August 2011 • Vol. 100 • No. 8
Bryce Ruiz, president and CEO; Fred Ruiz, co-founder and chairman emeritus; and Kim Ruiz Beck, chairman.
Also Inside: • Pack Expo Pre-Show Coverage • Hot Products Guide
www.snackandbakery.com
6 RECYCLABLE
Kwik Lok Is The Bag Closure Of Choice When It Comes To Function, The Environment And Consumer Convenience! Environment The Kwik Lok Bag Closure is designed to be reused and RECYCLED. The closure has earned a recyclable symbol of 6, making Kwik Lok a truly recyclable closure. Other closures, such as wire surrounded by paper or plastic, or polyvinyl and polypropylene tape with paper between the two ends, cannot be recycled. Wire and tape closures are typically thrown into the garbage each and every time, seldom ever reused. During our extruding process, no processed water is used or expelled into our city’s sewer system. Kwik Lok cools its extruders within a closed loop cooling system. Our new enhanced filtration system prohibits nearly all particulates from being expelled into the air. Kwik Lok is actively seeking to reduce our electrical demands by inventing and installing new, efficient closure manufacturing machinery. No hardeners or additives are added to our plastic. Newly developed additives such as PLA (Polyactide Acid), Polystarch or others are not used. Such additives, while claiming to make plastic degradable, present a couple of problems. (1) Recycling of products made with additives is problematic. The Biodegradable Products Institute concurs, “The recycling of plastic products made with these types of additives is poor, the plastic products have to end up in the landfill ... they cannot be recycled in their original form.” (2) The use of these additives creates methane gas which is 20 times more potent than carbon dioxide emissions! Every landfill has a different content, be it wet or dry, compost, or general waste, mixed with or without moisture and oxygen. Thus the process of degrading is highly dependent upon each landfill’s composition. Should the Kwik Lok closure be tossed into the garbage, its degradation process began at the moment the closure plastic left the extruder since no inhibitors or additives were added to the Kwik Lok. When you compare the choices, Kwik Lok, wire or tape ... Kwik Lok is the logical answer to your bag closing requirements.
($6<723(1
($6<7&/26(
($6<75($'
Convenience Kwik Lok is easy to remove. Many consumers have health issues such as arthritis, diabetes, and degenerative eye problems. For vision impaired customers and/or those with arthritis, the Kwik Lok is easy to remove. A person with totally impaired vision can remove a Kwik Lok closure. There is no guessing which way to untwist like you have with a wire closure. Attempt to find the ends of sticky tape and have the dexterity to separate the ends! It takes three hands to remove this closure, and it certainly is not reusable. The Kwik Lok Bag Closure is one of life’s little conveniences that plays an important function in packaging. It Closes the Bag Securely. It can carry Best Before Dating, or Country of Origin Labeling. It is manufactured with a low carbon output. It is degradable. It is recyclable. It’s Resealable, it’s Reusable, it’s REMARKABLE! Kwik Lok ... the Logical Choice ... Recyclable Bag Closure ... Convenient Bag Closure ... High Quality Dependable Bag Closing Machinery ... Date Coding on the Closure ... High Quality Custom Printed Closure Labels. Kwik Lok’s 893 Automatic Bag Closing Machine closes bags at 110 per minute and permits the packager to close bags with our standard Kwik Lok Closure or Closure-Labels.
CALL US TOLL FREE 1-800-688-5945
&25325$7,21
(;(&87,9(2)),&(32%2; <$.,0$:$ 7(/(3+21( RU )$; ,QWHUQHW ZZZNZLNORNFRP
Contents
Cover Story 12 | On the Fast Track When it comes to frozen foods and snacks, the folks at Ruiz Foods mean business. In fact, this third-generation, family-owned, Dinuba, Calif.-based company is raising the bar by introducing a slew of snack SKUs and showcasing new packaging lines. Find out how Ruiz Foods continues to stay on the fast track to success.
Plant Story Photos courtesy of Ruiz Foods
20 | Quick-Change Artists
Columns
Despite the economy’s ups and downs, Ruiz Foods still processes more than 200 retail and foodservice items in three facilities and boasts an estimated $450 million in sales. Take a tour of its 260,000-sq.-ft. headquarters plant in Dinuba, Calif.
20
6 | Editor’s Note A busy summer brings plenty of baking and snack activities, says Editor-in-Chief Lauren R. Hartman. Take a load off and flip through this issue to find out what the baking and snack industries have up their smocks.
32 | The Nutritional Corner Folic acid gets its time to shine, says contributing columnist GFF president Judi Adams. Find out how folic acid fortification earned a well-deserved place in a healthful diet.
73 | Engineering Management Many managers tout the word “team,” but don’t really know how to bring their team together to work in unison. Contributing columnist Jeff Dearduff offers some insight on how to make teams work.
88 | The Final Word Extreme couponers are forcing retailers to review, and in some cases, change their coupon policies, says Executive Editor Marina Mayer. Read on to find out what retailers are doing to regain control of their bottom line.
2
Snack Food & Wholesale Bakery - August 2011
www.snackandbakery.com
Contents Market Trends
28
28 Baking a Better Bread Bakers continue to reinvent the basic building blocks of artisan bread b y offering consumers a healthy halo of better-for-you options.
New Products 31 New Products
31
Read about some of the most recently introduced products, including WhoNu? nutrition-rich cookies from Suncore Products, Black Lava Coco almonds from Society Hill Snacks, Kashi TLC pita crisps and deep-dish brownies from Sanders Candy.
Production, Technology & Product Development Solutions for a Changing Industry. August 2011 Vol. 100 No. 8
For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail
[email protected] www.snackandbakery.com
John Schrei Publishing Director
[email protected]
Tom Imbordino Group Publisher
[email protected]
Jeff Heath Publisher
Ingredient Technology 57 Spread the Word about New Fats and Oils
57
Several ingredient suppliers provide a wealth of fats and oils that deliver on taste, texture and functionality, all while significantly lowering fat content. Here’s a peek at some of the new products allowing bakers and snack producers to reformulate their products and provide healthier options.
Production Technology
70
70 Divide, Round and Conquer
[email protected] 224-554-9154
Editorial Lauren R. Hartman Editor-in-Chief
[email protected] 847-405-4015
Marina Mayer Executive Editor
[email protected] 847-405-4008
Patty Catini Art Director
Advertising & Internet Sales Barbara Szatko Senior Sales Manager
[email protected] 630-527-9927
Suzanne Sarkesian Classified Sales
Dividers and rounders are vital to producing perfectly shaped breads, rolls and other bakery applications. Here are some of the most recent advances in technology that facilitate smooth production.
[email protected] 248-786-1692
Jill L. DeVries Corporate Reprint Manager
[email protected] 248-244-1726
Support Services
TT-1 Tortilla Trends
Nann Barkiewicz Production Manager
Check out this guide to learn about the highlights of the show, exhibitor/ attendee info and how some tortilla producers are contributing to the rise in industry sales.
Liz Wright Marketing Coordinator
Special Report 75 | Hot Products Guide 2011 Check out this flurry of hot new products from Arizona Instruments, Bay State Milling, Koenig and Sifter Parts & Service.
[email protected] [email protected] 248-786-1652
Audience Development
Pack Expo PreShow Coverage 64 | The Power of Packaging The power of packaging is contagious. That’s why PMMI, the Reston, Va.based organizers of Pack Expo 2011, is presenting one powerful show, Sept. 26-28 at the Las Vegas Convention Center in Las Vegas. Flip through this show guide to find out what the show details entail and what attendees can expect to see that’s new and improved.
SNACK FOOD & WHOLESALE BAKERY (ISSN 1096-4835) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: SNACK FOOD & WHOLESALE BAKERY, P.O. Box 1080, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 1312639 23. Send returns (Canada) to Pitney Bowes, P.O.Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to SNACK FOOD & WHOLESALE BAKERY, P.O. Box 1080, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or
[email protected].
4
Snack Food & Wholesale Bakery - August 2011
Kourtney Bell Audience Development Manager Stephanie Hunt Multimedia Specialist Carolyn M. Alexander Audience Audit Coordinator List Rental Postal contact: Kevin Collopy at 800-223-2194 x684
[email protected]
Email contact: Michael Costantino at 800-223-2194 x748
[email protected]
BNP Corporate John R. Schrei Publishing Rita M. Foumia Corporate Strategy Ariane Claire Marketing Vincent M. Miconi Production Lisa L. Paulus Finance Michael T. Powell Creative Nikki Smith Directories Marlene J. Witthoft Human Resources Scott Krywko Information Technology Beth A. Surowiec Clear Seas Research BNP Media Helps People Succeed in Business with Superior Information
www.snackandbakery.com
TM
@cjYMcifFU]g]bgWca
Editor’s Note
hh, summer. It’s so fleeting, and it’s hard to believe that it’s August already. After completing our two-issue State of the Industry reports on baking (June 2011) and snacks (July 2011), we’re coming down to earth and going back to our regular feature format. This month, we’re presenting Ruiz Foods, a Dinuba, Calif., manufacturer that processes more than 200 retail and foodservice items in three facilities. No small feat. Ruiz is a powerhouse on the West coast, boasting an estimated $450 million in sales. So successful is this third-generation, family-owned company that it’s launching a host of snack products and starting up new packaging lines. We take a look at how Ruiz does it all, Lauren R. Hartman and manages to keep
[email protected] pace with its customers through a view of its 260,000-sq.-ft. plant. We’re also featuring our semi-annual Tortilla Trends supplement in this issue, filled with important new tortilla product developments, trends, takes on the industry and consumer demands from some of the industry’s key manufacturers. The special report also includes a rundown of the most current details about this year’s TIA Convention, Sept. 12-13 at Caesar’s Palace in Las Vegas. Produced by the Tortilla Industry Association (TIA), Arlington, Va., the TIA Convention is expected to be a hit, as it is the most important event for tortilla and flatbread manufacturers, producers, suppliers, consumers
A
6
Snack Food & Wholesale Bakery - August 2011
and others involved in this growing industry. The TIA Convention will spotlight equipment, materials, ingredients, packaging and services all in one place. The conference registration includes educational sessions, lunches, a welcome reception, an entertainment banquet and entrance into the exhibit hall. Additional tickets may be purchased for guests, the welcome reception, the entertainment banquet and golf during the registration process. Speaking of Las Vegas, I am incredibly familiar with all things Pack Expo, and this year’s show, also held in Las Vegas Sept. 26-28, again promises to meet everyone’s expectations in terms of new packaging technology, machinery, materials, design and more. I covered this huge packaging show top to bottom during my 27 years as an editor at Packaging Digest, so I can safely say that it is probably the most important show in North American manufacturing, if not one of the most important in the world. It boasts 1,600 exhibitors, more than 25,000 attendees, an enhanced conference program hosted by key industry professionals, dedicated specialty pavilions and plenty of state-of-the-art equipment and systems around. This year’s Pack Expo is especially significant, as PMMI, Reston, Va., is partnering with the Snack Food Association, Arlington, Va., to launch a baking and snack break
lounge an industry-specific lounge, industry-specific meeting place for the baking and snack industry professionals to connect with suppliers and partners. Kliklok-Woodman, Decatur, Mich., will be its first corporate sponsor. So be sure to check out our action-packed Pack Expo Show Guide in this issue. If that’s not enough, take a look at our special issue 2011 Hot Products Guide, filled with a variety of new finished products, equipment and ingredients to whet your appetite for the months ahead. And that’s just for starters, not to mention an artisan bread update in our Market Trends section and hot topics from our columnists. So enjoy a bit of summer reading here, and don’t forget to contact me at hartmanl@ bnpmedia.com to keep us posted on breaking news. SF&WB
www.snackandbakery.com
Your customers and the future... "U1VSBUPT XFCFMJFWFQFPQMFXJMMDPOUJOVFUPBUUBDINPSFBOENPSF JNQPSUBODFUPUIFRVBMJUZPGUIFJSGPPE5IBUJTXIZXFNBLFJUPVSNJTTJPO UPEFWFMPQVOJRVFJOHSFEJFOUT UFDIOPMPHJFTBOEBQQMJDBUJPOTUPIFMQCBLFST QBUJTTJFSTDIPDPMBUJFSTBSPVOEUIFXPSMEUPCFTVDDFTTGVMXJUIUIFJSCVTJOFTT 0VSGPDVTPODPOTVNFSQSFGFSFODFTGVSUIFSSFJOGPSDFTUIJTDPNNJUUNFOUXJUI UIF1VSBUPT4FOTPCVT BNPCJMFTFOTPSZMBCPSBUPSZXIJDIDSFBUFTBDPNGPSUBCMF FOWJSPONFOUGPSDPOTVNFSTUPTIBSFUIFJSPQJOJPOTXJUIVTBCPVUUIFJSFWFSZ EBZGPPEOFFETFind out more at www.sensobus.us Contact Puratos today for your unique solution!
1VSBUPT$PSQPSBUJPOt5FMt'BYtXXXQVSBUPTVT
Business Briefs
supplier news
News
Blommer Chocolate reached a key corpo-
ASB Makes Improvements, Changes to Baking Tech 2012
rate social responsibility goal by sourcing
he e-newsletter published by the American Society of Baking, Sweedesboro, N.J., says ASB will be making some changes to its BakingTech 2012 meeting based on attendee/member requests, These changes are designed to encourage “more education, more networking and more fun.” There will also be more breakout sessions (10 total) on education and technical sessions with 25 individual presentations and two industry panels. Surveyed attendants also asked for more details on topics such as energy savings, niche products/baking, gluten-free production, new technology for niche production, engineering team development, market demographics, automation/versatility, sustainability, more ingredients technology, international sourcing of ingredients, safety/ sanitation, BISSC and more. ASB reports it also will continue to offer the MarketPlace in Motion event, but it will be tweaked to reflect requested changes. For more details, visit www.asbe.org.
sustainability program, which provides tools and training to increase yields and
T
more than 10,000 metric tons of Rain Forest Alliance-certified cocoa. More than 40,000 cocoa farmers are involved in the
income while practicing sound environmental stewardship. Bay State Milling broke ground on a 4,000-sq.-ft. innovation center at its corporate headquarters in Quincy, Mass. The center, named the Rothwell GrainEssentials Center, is an environment that stimulates creative design and delivery of grain-based foods using Bay State Milling’s value-added flours and grain blends with a strong focus on health and wellness. The facility will include smallscale, commercial-grade equipment for producing bread items, pizza, breading, tortillas and more. The center is scheduled to open next month. Ecolab received a 2011 IFT Food Expo Innovation Award for Exelerate ZTF, de-
BEMA Introduces New Baker Viewpoint BEMA, Overland Park, Kan., introduced a new format, the Baker Viewpoint, at its 2011 Annual Meeting, held June 23-28 in Santa Barbara, Calif. BEMA’s annual meetings are designed to bring together bakers and suppliers in a relaxed atmosphere to network and form relationships. This year, BEMA hosted an opening reception, a 60’s theme party, a beach party and the black-tie, Oscar-themed Chairman’s Dinner, in addition to the business sessions and industry expert
question-and-answer session discussing commodities, capital investments and areturn on those investments. In addition, the Baking Industry Forum, a group of five bakers and five suppliers who work together to address industry issues, presented their views on a number of issues as well as association leaders provided updates on their respective associations. To learn more about the speakers and the industry expert panel, go to www.snackandbakery.com.
Editor’s Note: Go to www.snackandbakery.com to learn more about other news items relating to the snack food and wholesale bakery markets, or subscribe to Operations Weekly and receive news directly to your inbox every Wednesday.
signed to address zero trans-fat oil buildup in food processing environments. Exelerate ZTF helps food manufacturers clean zero trans-fat residue from processing equipment and surfaces in half the time of other cleaning methods, thanks to a gelled product application that clings to equipment and surfaces. Viterra acquired the assets and inventory of Premier Pulses International Inc., a processor and merchandiser of peas and lentils with a facility in Minot, N.D., and a marketing office in Lewiston, Idaho. The Minot facility offers pulse cleaning and processing services and a finished product warehouse where a variety of locally sourced peas and lentils are stored, processed, bagged and shipped to destination customers worldwide. ToolBox Software GmbH celebrated 15 years of being a part of the baking indus-
Continued on page 11
8
Snack Food & Wholesale Bakery - August 2011
www.snackandbakery.com
BE HERE TO FIND
100% Food-Focused Technology To get the first look at next year’s technology, be here for this year’s largest all-food processing and packaging equipment show: Ąŕŕ 1ŕ' "#( ,3ŕ ,)'ŕ." ŕ1),& č-ŕ& #(!ŕ-/**&# ,Ąŕŕ/..#(!ŕ ! ŕ#(()0.#)(Ąŕŕ0 ,ŕ÷ùôŕ 2"# #.),-ŕėŕõôÿôôôĸŕ )) ŕ( ŕ 0 ,! ŕ.. ( Ąŕŕöýŕ")/,-ŕ) ŕ / .#)(&ŕ- --#)(-ŕ ) /-#(!ŕ)(ŕ )) ŕ - .3ÿŕ-/-.#( #&#.3ŕ( ŕ)." ,ŕ#--/ -ŕñŕ .#(!ŕ 3)/,ŕ',% .*& ŕĚ#(ŕ(!&#-"ŕ( ŕ*(#-"ě Bring the team...take home ideas.
NOVEMBER 1-4, 2011 – CHICAGO McCormick Place – South Hall
THE GLOBAL FOOD EQUIPMENT AND TECHNOLOGY SHOW™
Get the free mobile app at
"..*Āėė! ..!þ') # Scan tag to
REGISTER NOW!
REGISTER TODAY at www.myprocessexpo.com | 703.761.2600 ©2011 FPSA
THOUGHT-LEADER WEBINAR SERIES: PRESENTED BY:
www.hixson-inc.com
Anticipating the Next Generation Thursday, September 29, 2011 2:00-3:00 p.m. EDT Exclusively for thought-leaders in food and beverage processing facility management, Food Plant of the Future webinars are presented by Hixson, a leading design and engineering firm of food processing facilities in North America. Anticipating the Next Generation continues the dialogue about issues and advancements that will define how tomorrow’s food plants are built and operated. Can’t attend live? Register and watch anytime.
Register for free at webinars.snackandbakery.com
Business Briefs
people
Continued from page 8
supplier news try by throwing an anniversary party for its employees, customers and trade partners.
established in 2007 as a subsidiary of Ata Holding Group. It produces hamburger,
ToolBox provides warehouse and produc-
sandwich and Panini buns and pizza dough
tion management software to more than 600 bakeries in 30 countries worldwide.
for fast food restaurants. A study conducted by University of Florida
IOI Loders Croklaan received the 2011 IFT Food Expo Innovation Awards for its
researchers found that supplementing diets with galactooligosaccharide (GOS) during
SansTrans VLS30 and SansTrans VLS40 all-
periods of stress can help reduce symptoms
purpose shortenings, which are designed to reduce cost, saturated fats, calories and
of gastrointestinal dysfunction and support the body’s natural defenses. Corn Products
fat content in baked goods and snack foods. The award honors outstanding innova-
International’s Purimune GOS, a high-purity GOS powder containing a minimum of 90%
tion in products, ingredients, applications,
GOS, was featured
instruments, equipment, technology and services.
in the study, which was published in the June 2011 issue of The American Journal of
AMF Bakery Systems received a complete plant equipment contract for Ekmek Unlu Gida, located in Gebze, Turkey. Ekmek was
Clinical Nutrition.
DESIGNED
American Pan, Urbana, Ohio Michael Cornelis was named vice president of international sales. Cornelis brings more than 25 years experience in the baking industry and is an active member of the American Society of Baking, BEMA and the IBIE Committee.
M. Cornelis
D.D. Williamson, Louisville, Ky. Mark Murphy was named sales manager in North America, bringing 11 years of technical sales and management experience. Stratas Foods LLC, Memphis, Tenn. Ray Richard has been appointed senior vice president of risk management and procurement. Richard currently serves as an advisory board member of the Institute of Shortening and Edible Oils and second vice president of the National Institute of Oilseed Products.
for a smooth ride Look to the Horizon™… and move delicate articles without damage or seasoning loss. Key’s all new horizontal-motion conveyor lets you maintain blends, easily reverse conveying direction, and reduce noise. • Self-scrubbing – no ingredient build-up • Easy cleaning – wipe down friendly surfaces • Maintenance-free, lubed-for-life drive system
Slow-forward/quick backward motion eliminates product damage
• Up to 30 meters (100 Ƨ) in length Call 509-529-2161 now or visit www.key.net. There’s smooth product handling on the Horizon™.
© Key Technology 2011
www.snackandbakery.com
August 2011 - Snack Food & Wholesale Bakery
11
Left to right: Bryce Ruiz, president and CEO; Fred Ruiz, co-founder and chairman emeritus; and Kim Ruiz Beck, chairman, along with the rest of the Ruiz team continue to drive new ideas.
Photos by Ruiz Foods
New packaging, product positioning, brand promotions and a team of leade rs help drive Ruiz Foods’ growth, success and sales, making it one of the Top 500 Hispanic-owned companies in the United States. Marina Mayer, Executive Editor
12
Snack Food & Wholesale Bakery - August 2011
www.snackandbakery.com
W
hen it comes to introducing new products and staying on trend, food manufacturers must drive on the fast track. Even the slightest delay in a launch or the smallest of production interference can push a company behind the rest of the pack. But some companies come equipped with the right stamina, drive and persistence to keep up with the competition, regardless of what challenges lie in the road ahead. The folks at Ruiz Foods are the perfect example. From its first days producing bean and cheese enchiladas and chili rellenos, 46-year-old Ruiz Foods now employs approximately 2,500 people who process more than 200 retail and foodservice stock-keeping units (SKUs) at three facilities in its Dinuba, Calif.-based headquarters, as well as its Tulare, Calif., and Denison, Texas, plants. Louis Ruiz, the company founder, and his son Fred Ruiz, co-founder and chairman emeritus, began producing and selling frozen Mexican foods to momand-pop grocery stores in the San Joaquin Valley. Today, the third-generation company boasts an estimated $450 million in sales, and is ranked as the as the sixth largest
www.snackandbakery.com
Hispanic-owned company in the United States and the largest in California, according to Hispanic Business magazine. Just like any good race driver though, to stay ahead of the curve, leaders must instill a great team in the trenches. That’s why Fred, a 2006 inductee into the industry’s “Frozen Food Hall of Fame,” handed the responsibilities of president and chief executive officer over to his son, Bryce, and appointed his daughter, Kim Ruiz Beck, as chairman. “My dad always said, ‘If you’re not growing, you’re dying,’” says Fred. “As a result, Continued on page 14
August 2011 - Snack Food & Wholesale Bakery
13
Continued from page 13
we were very opportunistic and growthoriented. Today, Bryce and Kim have embraced the Ruiz family legacy and are as driven as my dad and I ever were. “I don’t exactly know when we became a national company, but there is a different dimension now,” he adds. “Bryce is not limited by the past and I think that it’s an advantage. Sometimes the past can be a burden and be limiting in terms of your outlook.” Ruiz Foods continues to stay on the fast track to success, even as other companies are riding a roller-coaster ride, and fending off economical woes. “Today’s consumer continues to look for quality, innovation, convenience and value,” Bryce says. The company’s outlook continues to remain bright, even as it hits the halfway point of 2011. According to data from Chicago-based SymphonyIRI Group, Ruiz Foods is the leader in the frozen Mexican foods category with a 24% dollar share for the latest 52 weeks, ending June 12. “We have consumer research that shows El Monterey is No. 11 among the top prepared food brands,” he says. “Moreover, of the top 20 frozen prepared foods brands, El Monterey is growing by 5.3%, which at the second fastest rate. That tells us there’s still a lot of opportunity, and that El Monterey is still a new idea in most households. We’ve been at this for so many years and just didn’t realize that our brand means as much as it does.” Behind the scenes, Ruiz Foods flourishes because of its advanced sales planning
AT A GLANCE
Company: Ruiz Foods
No. of Employees (Company-wide): 2,500
Headquarters (and plant): Dinuba, Calif.
KEY PERSONNEL: Co-Founder, Chrm. Emeritus: Fred Ruiz Chrm.: Kim Ruiz Beck Pres., CEO: Bryce Ruiz Sr. V-P., Supply Chain: Brian Miller V-P., Foodservice, Sales & Mktg.: Kimberli Carroll
Plant Locations: Tulare, Calif.; Denison, Texas Products: Frozen hand-held entrees and snacks Brands: El M onterey, Tornados Distribution: National
schedules (more than a year out). “Today, we’re looking out further,” says Bryce. “When you think more strategically, you can better utilize your funds. Although marketing and sales teams have not grown, we’re doing more and becoming more focused on our core. Our theme is, ‘Fewer. Bigger. Better.’ Let’s do fewer things, think bigger and then execute to a T.” To coincide with its bigger and better theme, in January 2010, Ruiz Foods launched Tornados, created to give it more elbow room to branch out from Hispanic flavor combinations and into broader varieties. The 3-oz., hand-held snack consists of freshly baked flour tortillas rolled in a crispy
seasoned batter and stuffed with savory meats and melted cheese. They come in Ranchero Beef & Cheese, Grilled Chicken & Cheese, Chicken Club, Southwest Chicken, Cheesy Pepper Jack and Cheesy Pepperoni varieties. Then, Ruiz Foods introduced an even larger mainline packaging shift, further targeting the multi-serve, snacking occasions. In May 2010, Ruiz Foods repackaged 12 different El Monterey retail products— everything from six-count tamales and quesadillas to 14- and 16-count taquitos and mini chimichangas—by upgrading the packaging graphics and photography for the first time. “This takes all the complexity out for retailers,” says Bryce. “No longer will we have one-off items, such as tamales, in meat-style trays. Now we can bundle all of our El Monterey brand equity with a common look and common price points. This will give us greater presence across a full door, while it makes it easier for retailers to feature and display our products.” For instance, the El Monterey snack bag line features a resealable standup pouch, and includes flour and corn tortillas, Chicken and Shredded Beef taquitos, Southwest Chicken taquitos, two kinds of mini chimis, quesadillas (Chicken and Continued on page 16
14
Snack Food & Wholesale Bakery - August 2011
www.snackandbakery.com
h\Y
D9F:97H 6@9B8 CUTTING EDGE TECHNOLOGY AND THE ART OF OLD WORLD BAKING
Sours | Dough Improvers | Bases, Mixes and Concentrates | Grain Blends | Specialty Products
gdYW]U`hm dfcXiWhg For over 75 years, Brolite Products and its specialty ingredients have been creating solutions for difficult baking problems. From egg replacers and pastry washes to icing stabilizers and pan releases, Brolite has the “Perfect Blend” to solve your most difficult baking problem. Call us today.
1900 S. Park Ave. | Streamwood, IL 60107 | Toll Free (888) 276-5483 (630) 830-0340 | Fax (630) 830-0356 | www.bakewithbrolite.com
the
solution
distribution tna offers the ultimate in distribution technology and endless possibilities with horizontal and vibratory systems.
Party With a Purpose A company trying to exceed last year’s sales goals isn’t really news, especially since most companies make that a primary goal. But, a company trying to break its annual nonprofit fundraising record? Now that’s newsworthy. Since 1990, Ruiz Foods, Dinuba, Calif., has raised more than $2 million to fund Ruiz 4 Kids, a non profit organization supporting area children’s programs. On Oct. 7, more than 600 people attended the event, which included dinner, a silent auction, dance and games at the Visalia Convention Center, Visalia, Calif., and helped Ruiz Foods raise $197,000, the largest annual figure in its nonprofit’s history. The money portioned out to help fund the Boys and Girls Club of the Sequoias, CASA of Tulare County, Family Services of Tulare County and the Visalia Police Activities League. “We are proud to support each of these nonprofit organizations,” says Kim Ruiz Beck, chairman of Ruiz Foods. “We couldn’t be more pleased with the results of our 2010 fall fundraiser when we recognize the fundi ng cutbacks affecting organizations serving children. Although we see some ease in the economic crisis, it will take longer for nonprofit organizations particularly those depending on donors and grants to recover.” Continued from page 14
See our innovative distribution technology for yourself at Pack Expo, 26 - 28 September, Stand 5135, or visit us at tnasolutions.com.
distribution spraying seasoning weighing metal detection verification packaging promotion cutting simply scan the code and learn more
mark lozano » national sales manager p: +972 462 6500 » m +312 560 8665 f: +972 462 6599 tna north america
[email protected]
Stay in touch with tna Follow us @ tnasolutions
Search tna solutions
YouTube Channel tnasolutionsmedia
Search tna solutions
tnasolutions.com
Shredded Steak) and tamales (Chicken and Beef). The El Monterey 2-pack burritos and chimichangas are packaged for the one- to twoperson household and consist of similar items as above. El Monterey Supreme burritos, butcher-wrapped burritos, XX large burritos, chimichangas and the Gigante burritos are manufactured specifically for the convenience store customer, as they look for products for their hot case, microwaves, freezer, etc. These lines entail the same recipes of freshly baked tortillas, real cheeses, authentic Mexican spic es and chunks of white chicken meat or shredded steak.
Full speed ahead In addition to its lineup of new products and packaging initiatives, the past few years have been historic ones for Ruiz Foods and its El Monterey and Tornados brands. For starters, in 2009, Ruiz Foods teamed up with Stewart-Haas Racing (SHR), the NASCAR Sprint Cup Series team, to sponsor SHR driver Ryan Newman. Newman represents Ruiz Foods’ convenience store and retail snack brand, Tornados, in the NASCAR competitions. In October 2010, Ruiz Foods sponsored Newman in a nationwide series car featuring the company’s El Monterey brand at Fontana’s Auto Club Speedway. This year, Tornados continued its Ryan Newman NASCAR sponsorship and El Monterey became an associate sponsor of Tony Stewart, another SHR driver. In the fall of 2010, the National Association for Stock Car Auto Racing (NASCAR) also treated 300 of Ruiz Foods’ team members to hospitality events, garage tours and pace car lap activities. (A month
later, approximately 250 team members at Ruiz Foods’ Denison, Texas, plant enjoyed the same NASCAR treatment in Dallas.) “Just think. More than 300 team members got on a bus at two in the morning to do this [NASCAR trip],” Bryce says. “For many, this was their first exposure to the NASCAR, and after visiting the hospitality
tent, touring the track and more, they had a great time and the full experience. It really created a team-building atmosphere.” “Such an event would’ve surpassed anything my dad ever thought it would be,” Fred says. “The most important thing he talked about was that we build a brand. He also talked about investing in your business, automating and becoming a low-cost manufacturer. If we could build a brand and do that, we could compete against anybody.” Recently, Ruiz Foods showcased its Tornados Sampling Tour at the Kentucky Motor Speedway on July 9. Staff in a 27-ft. painted-out truck produced more than 1,000 Tornados an hour and distributed Tornados coupons redeemable only at Thortons convenience stores in Kentucky. A full-size NASCAR #39 Tornados Sprint Cup Series racecar accompanied the tour. “In most markets, we overlay the promotion with radio and geo-targeted social
media to drive awareness to our customers’ locations,” says Kimberli Carroll, vice president of foodservice sales and marketing. “To date, our Tornados Sampling Tour promotions have been very successful, so much so that we are already committed to continue our NASCAR customer promotions in 2012.” Ruiz Foods also finalized developing promotional campaigns with six Six Flags locations (Six Flags Great Adventure in New Jersey is home to a Tornados Zone ride).
Media maneuvers Ruiz identifies NASCAR dads as its core cstore shopper. That’s why it developed the company’s first multi-media promotional campaign, complete with in-store merchandising materials, social and digital media and 30-second TV spots. Themed “Full Force Flavor. Full Force Fun,” the spot ran in metro markets on SPEED TV, which Continued on page 18
Continuous Seasoning and Coating Systems We provide fully integrated systems and individual machines to fit your application. If you need a versatile system that offers consistent and accurate control when applying your dry and LIQUID COATINGS THE 1UIK #OAT SYSTEM IS THE ONE FOR THE JOB For drum coating applications TO OVER BELT TOPPING APPLICATIONS &//$ESIGN PROVIDES QAULITY integrated coating systems for your application. #ALL TODAY OUR APPLICATION AND equipment specialists can provide YOU WITH A 1UIK #OAT SOLUTION FOR your seasoning and coating application.
www.snackandbakery.com
s (EAVY DUTY DURABLE DESIGN FOR continuous operation s %ASY TO CLEAN SANITARY UNITS THAT MEET FDA and USDA requirements s "ACKED BY &//$ESIGNS PROVEN experience and innovation
August 2011 - Snack Food & Wholesale Bakery
17
Continued from page 17
reaches the NASCAR family. “This was a case where, because you have family working this business, we allocated the extra funds,” says Bryce. “Although a national ad campaign was not in the plan, it reflects the family’s commitment to our brands.” A young dad himself, Bryce led Ruiz Foods into social media first creating a Facebook page for Tornados fans, and then a second page just for El Monterey lovers. “I quickly understood the potential of social media for our brands,” he says. “And looking back, I believe I was right. In 2010, our two brands received more than 2 billion impressions and drove more than 3.5 million brand engagements on Facebook.” As of press time, the Tornados page alone boasts 353,000 fans. “[Social media] gives us a way to ‘activate’ our brands and engage our consumers. It gives us a platform where we can
solicit flavor ideas, recipes and even have some fun with our fans. We also found that the average fan spends five to seven minutes interacting with the medium,” says Bryce. Ruiz Foods continues to demonstrate its willingness to take its message to just about any media channel by introducing a media mix of NASCAR, television, in-store promotions, YouTube channels, advertising, Facebook and other social media channels to boost brand awareness and increase exposure. For instance, in February, Ruiz Foods launched a three-month campaign for its El Monterey brand that included traditional 30-second commercials, which were themed after a comical telenovela (Spanish soap opera) and starred a fictional family (the El Montereys) bound by their love of El Monterey food. There were six total spots, each one featuring a comical “episode” from the El Monterey soap opera. Three of the spots
aired on network and cable TV, whereas three aired as YouTube videos, scoring millions of impressions within three months. At the store level, Ruiz Foods featured large floor graphics in the frozen aisle
with an image of the telenovela family. On Facebook, the El Monterey Hacienda Challenge gave fans the opportunity to submit their own story line for the El Monterey telenovela. Fans received a chance to win prizes like digital cameras, t-shirts or a grand-prize trip to San Diego. The Hacienda Challenge generated more than 350,000 engagements and an additional 35% Facebook likes. In addition, Ruiz Foods continue to use free-standing inserts as part of its customer support and consumer trial initiative for events such as the Super Bowl, Cinco de Mayo, back to school, and more. “We’re not doing anything different from 10 years ago,” says Bryce. “There may be different [communication] media and different business cycles but the rest is the same. My last name is on the building just like it is for dad, Kim and our other family members. We believe in this business. Today, it’s just a matter of how
we’re going to go about growing it. And then, let’s go.”
Meeting mom at the finish line In addition to the company’s noteworthy NASCAR consumers, Ruiz Foods also strives to meet mom (the other core grocery shopper) at the finish line. In doing so, in March, Ruiz Foods partnered with the National Sodium Reduction Initiative to help cut the salt by 20% over the next five years. To date, its entire line of El Monterey family-pack burritos and chimichangas are already in line with the 2012 guidelines. Ruiz Foods also established sodiumreduction plans for the remaining SKUs to better partner with the NSRI goals. “The consumer typically grows with their ethnic food choices,” Bryce says. “For example, when they begin to enjoy Mexican, they will begin with the basic burrito. As they become familiar with
Equipment - Installation - Parts - Service
Mexican flavors, spices, levels of heat, etc., that same consumer becomes both willing and interested in trying new and innovative flavor profiles and textures.” Therefore, Ruiz Foods is driven to provide the best-of-the-best products with a healthier label. “Our greatest opportunity is two-fold,” Bryce says. “One, to maintain our high level of quality in the products we currently offer our consumer and two, to continue to listen to what our consumer is looking for. Convenience? Value? New textures? New flavors?” Whatever the consumer is in search of, Ruiz Foods has the drive, passion and ability to continue positioning itself in the fast lane. SF&WB
Editor’s Note: Parts of this article were written and published in the January 2011 issue of Refrigerated & Frozen Foods, a sister publication of Snack Food & Wholesale Bakery.
Koenig Bakery Systems Rich Breeswine, General Manager + 1-804-564-3997
[email protected] www.koenigusa.com
Let our high efficiency lines improve your profits and put your company on a roll. Contact us today for an efficiency evaluation!
www.snackandbakery.com
August 2011 - Snack Food & Wholesale Bakery
19
QUICK-CHANGE ARTISTS Quick changeovers and enhanced technologies help Ruiz Foods’ Dinuba, Calif., plant meet ever-changing consu umer demands. Marina Mayer, Executive Editor
hen it comes to consumers, no two are alike. While one wants quality, the other wants quantity. While one seeks out better-for-you ingredients, the other is in search for the most eco-friendly packaging. This may put some food manufacturers in a bind to please the every-consumer, but for companies like Ruiz Foods, there’s an art to staying ahead of the game. “Every day, the complexity increases in our business. You can’t just sell the same box of macaroni and cheese,” says Brian Miller, senior vice president of supply chain for Ruiz Foods. “Consumers are quite different t oday and it’s almost as though we’ve become a restaurant. We’re developing new products all the time. Whether it’s out of boredom or something else, consumers demand more flavor and flair.” That’s why Ruiz Foods, producer of frozen, hand-held entrees and snacks, remains flexible in its 42-acre, 260,000-sq.-ft. plant, and continues churning out as many as 200 distinct stock-keeping units (SKUs) for re tail, foodservice and club store channels. For starters, this 20-year-old plant dramatically retooled and reconfigured several packaging lines, discontinued several bag-in-box packages and other formats and converted as many as 12 different food packages to stand-up recloseable, zippered pouches for tamales, mini chimichangas an d taquitos, among others.
W 20
Snack Food & Wholesale Bakery - August 2011
www.snackandbakery.com
Photos courtesy of Ruiz Foods
Operators hand roll freshly baked tortillas filled with chicken, cheese and Mexican spices for El Monterey Chicken and Cheese Taquitos. “Many companies would have needed 6-8 months to change production and packaging, yet we did it within 90 days,” notes Miller. “We’re definitely a ‘branddriven’ facility with the same type of mindset and environment as a copacker. We have to be flexible and oriented toward customer service. We’re going to deliver to our sales and marketing plans, no matter what.” The plant is also home to six production lines, 10 packaging lines, a raw materials warehouse, a tortilla bakery, production and a finished goods storage room. The plant runs 24 hours, six days a week, with 15-17 hours of production alternating with sanitation, preventative maintenance and food safety activities.
Making its mark To be successful, Ruiz Foods needs to em-
ploy good people who can bring passion, dedication and diligence to the front lines. That’s why it helps to have a veteran workforce. For example, of the 1,650 employees, 511 joined the company 10 years ago and another 144 have 20 years of tenure. Since the Dinuba facility opened in 1990, Ruiz Foods has attracted hundreds of workers within a 40-mile radius, and has even employed two generations of families. It’s these ongoing relationships that have helped Ruiz Foods reach some noteworthy achievements, Miller says. “Eight or nine years ago, repetitive motion activities put us in a high-risk category for workers compensation,” says Miller. “Then we developed a program involving job rotations, job qualification standards, preventative injury exercises and other disciplines, so team members are doing various things throughout the week.
Years ago, our injury index was seven or eight (injuries per business hour), which was comparable to the industry standard for a company our size. Today, we’re at an index rate of 1.5 and in our shipping and receiving area alone, we’ve accumulated more than 3,650 days (or 10 years) with no loss-time accidents.” When it comes to food safety, Ruiz Foods takes extra measures to inspect raw materials coming and finished products going out. “We handle allergens and high-risk ingredients such as chicken, beef, pork, cheese, eggs and other items,” Miller says. “Because of the high risks associated with adulteration or bacteria, we inspect at least 98% of all raw materials entering the plant. In 2010, we even exceeded that standard, even though we handle as many as 200 different product SKUs.” Continued on page 22
www.snackandbakery.com
August 2011 - Snack Food & Wholesale Bakery
21
Continued from page 21
Additionally, Ruiz Foods issues a quarterly bonus program with three parameters, says Miller. “Our goals are 98% first-time quality, schedule attainment of 95% or better and no equipment damage inflicted by team members. We’re giving more [equipment upkeep] ownership to team members and believe in a system where 1,600 peers help each other achieve success. Last year, our factory’s average hit 99.5% for product ‘right first time.’ We also review first-time quality against a consumer complaints measure. For a factory our size per millions of items produced, the industry average is five or six pieces per million (drawing complaints). Our goal was 1.3 eaches per million and we achieved just 0.91 million.”
“Fresh-frozen” process To produce the best-quality product, the folks at Ruiz Foods treat taquitos the Continued on page 24
22
Snack Food & Wholesale Bakery - August 2011
Taquitos are packed in stand-up, reclosable pouches that travel along a conveyor to receive code date registration, and are then sent to the automatic casepacking l ines.
www.snackandbakery.com
Kemper Bakery Systems USA Subsidiary of the WP BAKERYGROUP
Partner for Industrial Solutions WP BAKERYGROUP. As the worldwide leader in dough mixing; bread and roll make up; and sheeting, proofing and oven technologies, WP offers the experience to design, build and deliver your fully integrated Turnkey Bakery. WP performs as your single source supplier to control the entire process. WP provides the answers to consistent product quality and efficiencies. WP – Your Partner in Success. Kemper Bakery Systems, Ltd. 3 Enterprise Drive, Suite 108 . Shelton, CT 06484 . USA Phone 203-929-6530
www.wpbakerygroupusa.com
VP & Director of Industrial Sales Jim Souza
[email protected]
Continued from page 22
same way a frozen vegetable plant handles beans with one-on-one care. “We are 100% self sufficient,” Miller notes. “This includes our own flour delivery system and a complete fresh tortilla bakery to how we blend our own spices and prepare all of our fillings on the factory floor within just a few hours of freezing. Even though our products are frozen, we ensure that each is ‘fresh-frozen,’ so when a consumer prepares it, it tastes as though it’s been cooked for the first time.” At the time of the plant visit, Ruiz Foods was preparing chicken and cheese taquitos. The pre-batch kitchen team members arrive at midnight to remove cheese and chicken from shipping boxes. These ingredients arrive at the cold mix room and are held at 40°F to ensure food safety and proper mixing consistency. “Our products require lots of mateContinued on page 26
Freshly made tortillas travel on a multi-level cooling rack before being transported to the taquito line.
Since 1922, the North Dakota Mill has selected and milled the finest quality wheat to create a superior line of flour known for its consistency and performance. We continue our tradition of catering to customers who set the highest quality standards in the industry and insist on baking with the best.
Call 1-800-538-7721 today
24
Snack Food & Wholesale Bakery - August 2011
www.ndmill.com
www.snackandbakery.com
Continued from page 24
rial handling because we don’t believe in ‘pump-in-place’ fillings,” says Miller. “We emphasize [ingredient] piece integrity, which is one way we differentiate ourselves with high quality.” Following computerized formula printouts, workers then add water, spices, green
chilies and other vegetables. Once the mixture reaches proper consistency, it’s dumped into a mobile stainless-steel tote, which are staged in a chilled holding area (and sampled by quality assurance technicians) before entering the production room floor. Two external flour silos feed flour (us-
STONELESS MASA MILL
8" - 1000 lbs/hr 12" - 2500 lbs/hr 18" - up to 6000 lbs/hr
Stainless Steel - Consistant Grind Profiles Adjustable Feed Rate - Manual Gap Control
0DMHVW\'DOODV7; )D[ ZZZDFKRUQFRFRP
26
Snack Food & Wholesale Bakery - August 2011
ing an air conveyance system) into the plant on a batch-volume basis. Pre-set amounts of flour and metered water are released into one of four large, upright mixers. After the blend is created, the dough is transferred into proprietary tortilla equipment where it’s formed and cut. The tortillas then travel onward through a continuous oven, where they bake for seconds before exiting at the other end. Wire conveyors then allow the tortillas to cool slightly before employees remove, stack and stage them for subsequent use on the line. Next, operators transfer filling mixtures into filling machines positioned beside each filling line. Once tortillas are placed on the production belt conveyor, they receive filling and are quickly folded and rolled via a proprietary process. Rolled and filled tortillas then head into a continuous fryer, which cooks for approximately 30 seconds. Operators then check the newly created (now golden brown) tortillas before they travel into a spiral freezer. Taquitos travel upward and exit the freezer in the second-story packaging room. Here, operators pack them in new stand-up, recloseable pouches, apply code date registration and feed them to automating casepacking lines. Ruiz Foods’ successful transition to stand-up pouch has officials considering even more new product and package applications, without expanding the plant’s existing factory footprint, Miller says. Team members also add their own outer case labels to track product in the plant’s adjacent storage freezer. Each Ruiz production line is flexible enough to process as many as six to eight different items, Miller says. And, even as pallet loads ship out to Ruiz Foods’ thirdparty distribution network, Miller says he and Dinuba team members remain focused
www.snackandbakery.com
International, Innovative, Inspiring
Shipping department members are responsible for the 3,650 days (or 10 years) of no loss-time accidents.
Ruiz Foods Celebrates 10 Years of No Loss-Time Accidents
T
he Ruiz Foods shipping department reached a milestone through the collective efforts of its Dinuba, Calif.-based team members. Through direction, support and the necessary tools, the shipping department accumulated 3,650 days (or 10 years) with no loss-time accidents. “From the Ruiz Foods perspective, safety is No. 1, whether it’s food or people,” says Brian Miller, senior vice president of supply chain. To reach this goal, Ruiz Foods installed state-of-the-art equipment, such as battery changing machinery, battery watering systems and impact records, in its 260,000-sq.-ft. plant. A digital counter was then placed in the warm-up room to count each day the department went without a loss-time accident. “At first, there wasn’t much attention paid to the counter, but once the number reached 1,000 days, and then 2,000 days, team members really started to notice, ask questions and make commitments to do their best,” Miller says. In addition, Ruiz Foods offered coaching, scheduled safety meetings, incentives and visuals to create awareness and excitement among the three-shift shipping department. The safety team even scheduled regular meetings to remind team members of their responsibility to producing great results. “Over half of the team members in the shipping department have been with the company 10 or more years,” Miller says. “This exceptiona l milestone shows safety is not only the Ruiz way, it’s their way.” on the next load to come. “We always challenge ourselves to come up with new ideas,” he says. “Our supply chain goal is to be the industry’s leader and ensure the best experience for any consumer buying frozen Mexican foods and flavorful frozen snacks.” Regardless of how often or how drastically consumers’ demands change, Ruiz Foods holds the skills and qualities to continue being quic kchange artists. SF&WB Editor’s Note: Parts of this article were written and published in the January 2011 issue of Refrigerated & Frozen Foods, a sister publication of Snack Food & Wholesale Bakery.
www.snackandbakery.com
Crusto bread line Specialist in food processing equipment • Low Stress Production of Cut and Molded Artisan Style Breads • Ideal for high absorption and pre-fermented dough’s • Product can be placed on pans, peels, or paper • Quick product changeover
Rademaker USA, Inc., 5218 Hudson Drive, Hudson, Ohio 44236, Tel. (330) 650-2345, Fax (330) 656-2802, Email:
[email protected]
www.rademaker.com
Market Trends Artisan Bread Photo courtesy of Chabaso Bakery
Baking a Better Bread As demand for all-natural, hand-crafted breads grows, artisan bakers are tying on their aprons and developing musthave products for consumers and retailers alike. Romy Schafer, Contributing Writer
hanks to mass production, American consumers have access to millions of affordable products designed to make their lives better and more enjoyable. The latest fashions, must-have electronics and convenience foods are readily available at the local big-box store or shopping mall, both usually just a short drive away. Yet it seems that more people nowadays are seeking out stores that sell one-of-akind products and buying all-natural, artisan foods at farmers’ markets and natural food stores. Why? Because they believe handcrafted products, especially artisan breads and other baked goods, are superior to similar items sold by mass merchants. But what exactly is “artisan” bread? It’s typically bread made in small batches using basic ingredients such as flour, yeast, salt and water. Artisan bakers use all-natural butter, eggs, garlic, cheese, nuts and herbs to create different types and varieties of artisan breads. For Cindy Helmling, owner of Cornerstone Bread Co., Indianapolis, artisan bread dough must also be shaped by hand. “That’s the main thing for me,” she explains. “We have a divider/rounder that rounds our hamburger buns, but the breads definitely have an element of the human touch to them.” The wholesale bakery handcrafts a
T
28
Snack Food & Wholesale Bakery - August 2011
variety of artisan breads for local restaurants, as well as for sale at farmers’ markets and a number of small grocery stores. “We do different breads on different days and during different times of the year,” Helmling says. “Most of our retail sales are at farmers’ markets, so we have kind of a three-week cycle that we run the breads through.” For instance, on the 4th of July weekend, the bakery introduced a rosemary-olive fougasse. The following weekend’s offerings included Rosemary Potato and Cherry-Chocolate bread.
Cornerstone Breads’ artisan breads sell for $3-6 per loaf, depending on size and ingredients. Dorothy Radlicz, director of marketing for Chabaso Bakery, New Haven, Conn., says most her company’s breads are “touched by hand—hand-scored or pulled into shape.” The bakery produces all-natural loaves, sticks, rolls, baguettes, boules and ciabattas, all of which are available direct-for-delivery or par-baked frozen. Chabaso Bakery also believes in keeping its ingredients basic and taking more time to bake its breads. “We don’t rush
www.snackandbakery.com
Market Trends the process,” Radlicz explains. “We do a lot of handwork and also work with small batches. That makes a difference.” Chabaso’s newest introductions exemplify the company’s commitment to value. The Classic Baguette and Sesame Semolina sandwich rolls come in four-packs with a suggested retail price of $3.29. The Classic Ciabatta and Rainin’ Grains Pull-Aparts come in 8-oz. packages with a suggested retail price of $2.49. The 8-oz. Olive Oil Mediterranean flatbread retails for $2.29, while the 6-oz. Sourdough Demi Boule has a suggested retail price of $1.79. Meanwhile, Eagle, Idaho-based Alexia Foods sources ingredients that offer “the best desired impact,” says Matthew Cardon, associate brand banager. “For example, we use 100% real butter in our garlic baguette because we know artisan breads should be made with real, premium ingredients,” Rolls, focaccia, ciabattas and biscuits comprise the company’s line of allnatural artisan breads, which was launched in 2006. Alexia Foods’ all-natural, frozen biscuits, classic French rolls, foccacia, ciabatta and whole grain rolls come in 10- to 14-oz. packages with a suggested retail price of $3.99. The 6-oz. Garlic Baguette is priced at $1.99. French Meadow Bakery also uses carefully selected ingredients to maximize the flavor of, and maintain its commitment to, high-quality products. The Eagan, Minn.-based company offers a variety of all-natural and gluten-free breads and rolls, including two recently introduced round breads Organic Summer bread, a light bread ideal for eating during warmer weather, and Organic Flax & Sunflower Seed bread, a naturally-leavened bread with a mild, nutty flavor. French Meadow Bakery’s 20-oz. Organic Summer bread and 24-oz. Organic Flax & Sunflower Seed bread retail for $5.99 each.
Consumer misconceptions Despite its premium ingredients, savory flavors and many formulations, artisan bread is still shunned by many consumers
Beyond Bread
L
eavened breads aren’t the only baked goods going artisan. Buns, muffins, crackers and quick breads made with wholesome ingredients are also appearing on retailers’ shelves. Ozery Bakery’s recently introduced Morning Rounds Toastable Fruit & Grain buns, for instance, offer on-the-go individuals a healthy, portable breakfast or snack option. “Our products are low-fat, all-natural and heart-healthy,” says Alon Ozery, co-founder of the Toronto-based company. Ozery’s Morning Rounds contain all-natural grains, real pieces of dried fruit and seeds and no preservatives. “We believe artisan breads should use as many unprocessed ingredients as possible,” says Ozery. “Time is a factor and ingredients must not be added to try and shorten proofing times. “To us, artisan is both a philosophy and a process. We started Ozery as a family-run sandwich shop in Toronto. At our shop, we baked fresh bread by hand every day, letting the dough rise slowly and using the best ingredients. We extend this philosophy to our packaged goods.” Morning Rounds are available in Cranberry Orange, Apple Cinnamon and Muesli. Six-unit packages are available for $3.49-$3.99 at many Whole Foods Markets and Sprouts Farmers Markets. Introduced in January 2011, Van’s Natural Foods’ individually wrapped Wild Blueberry and Triple Chocolate muffin crowns are also ideal for busy consumers. Both are made with whole grains, milk, eggs, soy and other ingredients. The former also contains real blueberries, applesauce, allspice, ginger and nutmeg; the latter is prepared with rich chocolate. Van’s muffin crowns are frozen to ensure they stay “at the peak of freshness” without preservatives, according to the company. They can be eaten out of the package or heated in a toaster, oven or microwave. Consumers can find them at grocery stores and fine natural food retailers nationwide at a suggested retail price of $5.49 for a four-unit box. “Artisanal breads will increase their market share,” Ozery says, when asked what the future holds for this category. “As consumers are educated that less and little may mean more (healthwise), they will invest in artisanal baked goods.”
Continued on page 30
www.snackandbakery.com
August 2011 - Snack Food & Wholesale Bakery
29
Market Trends Continued from page 29
for a variety of reasons, most of which could likely be addressed by in-store education. “They think that it’s not mainstream—that it’s a high-end product,” says Radlicz. “Our breads are very value-priced.” In addition, some consumers think artisan breads are an acquired taste. “While they’re certainly gourmet-inspired, anyone can enjoy these new and exciting flavors that help make a simple meal at home extraordinary,” says Cardon of the company’s artisan breads, some of which incorporate rosemary, extra virgin olive oil, cheese, garlic and flax and sunflower seeds. Most artisan bakers realize, however, that bold or unusual flavors may not be for everyone, and thus offer varieties they know will appeal to most consumers, like wheat or sourdough. Finally, store placement can also influence consumers’ perception of artisan breads. Consumers may question the quality and value of these products when they’re displayed alongside inexpensive sandwich breads and opt for the “safer,” less costly choice. Placing these breads near a store’s bakery, deli or produce section may encourage consumers to give them a try.
Going artisan Still, demand for artisan breads will continue too, as people seek out more flavorful and nutritious products. “Over the last 10-20
Your ultimate source for sifters, screens, fabric filters, transfer sleeves and rubber products!
CS
1
CONSTRUCTION – Sanitary; all metal magnesium alloy. APPLICATION – Accurate sizing of dry, free-flowing materials and sanitary sizing of dry foods and food products. SEPARATION – Feed sizes – 200 mesh to 1/4 inch. SCREENING AREA - 10 to 35 square feet available with 2 to 7 decks for separating into 2, 3, or 4 products. SANITATION – Easy breakdown for cleaning; optional inspection ports available.
Made In USA (Four deck, two separation, CS-1 sifter)
NEW & USED CS-1 SIFTERS, PARTS & REPAIRS All New
• • • • •
RS
1
All stainless steel construction Great for small batch sifting Capable of sifting up to 600 lbs/hr Adjustable height rolling base Interchangeable screen frames
SIFTER PARTS & SERVICE, INC. (800) 367-3591
30
sifterparts.com
Snack Food & Wholesale Bakery - August 2011
years, customers have become much more aware of what a good bread tastes like, and it’s not the fluffy, white bread of their childhood,” says Helmling. Emily Dingmann, marketing coordinator for French Meadow Bakery, agrees: “Consumers looking for a nutritious alternative to mainstream breads are delighted with the healthful aspects and flavor of artisan loaves.” Factors such as growing interest in local and fresh foods, foodrelated health issues and a resurgence of home-cooked meals are also impacting the artisan bread category. More artisan bakers, for instance, are offering gluten-free products for Americans unable to eat baked goods containing grains such as wheat, rye or barley. Likewise, budget-conscious consumers are using the money they save by preparing meals themselves to occasionally splurge on higher-priced ingredients or ready-to-eat products. “As more and more individuals choose to prepare meals at home, demand is growing for all-natural, gourmet-inspired meal ideas,” says Cardon. “Alexia’s line of artisan breads allows at-home cooks to prepare meals quickly, but without sacrificing quality or taste.” Furthermore, artisan breads’ smaller size may weigh in their favor too, because they encourage some consumers to try new flavors and purchase varieties that appeal to different family members.
Bakers’ challenges Despite growing demand for their products, artisan bakers still face a variety of challenges, particularly increasing competition. “There’s nationwide distribution of pretty good artisan breads now,” says Helmling, “so people like me have to be distinctive in terms of variety and quality and really stay on top of our game.” And, of course, there’s the issue of shelf life. “It’s a constant challenge to expand your business when you’re not doing multishelf life bread,” Radlicz says, explaining that the longer artisan bread sits on the shelf, the more it changes. Trying to find locally-grown ingredients can also be difficult, if not impossible. “How do you get locally grown flour in Connecticut?” asks Radlicz, adding that when such ingredients are available, their cost would drive up the price of the end product. Helmling faced similar challenges trying to find Indiana-grown wheat in a state known for its corn. However, “there’s a certain segment of the population that understands that supporting a local business and local grain growers means higher [end] costs,” she says. “I think the people who enjoy this type of bread are not going to go back to the soft, white bread. It’s just not what they want.” And that’s exactly what artisan bakers and their retail customers want to hear. SF&WB
www.snackandbakery.com
New Products
4
4
1 2 3
3 2
1
Black Lava Coco Almonds
Company: Society Hill Snacks, Philadelphia, Pa. Website: www.societyhillsnacks.com Introduced: July Distribution: National Suggested Retail: $9.99 for a 12-oz. bag; $19.00 for a 20-oz. canister; $29.00 for a 32-oz. container Product Snapshot: Mixing sweet with salty are Black Lava Coco almonds, which combines the company’s bestselling snacks—Loco Coco crunchy almonds and Black Lava nuts. This snack combines a complex blend of flavors and textures, beginning with premium roasted almonds coated in the company’s signature buttery cocoa glaze, then prepared in small batches in a vintage copper kettle. Then, the morsels are lightly dusted with black Hawaiian sea salt. Ingredients: Almonds, sugar, sea salt, cocoa, butter.
WhoNu? Nutrition-rich Cookies
Kashi TLC Pita Crisps
Company: Kashi Co., La Jolla, Calif. Website: www.kashi.com Introduced: June Distribution: National Suggested Retail: $3.19 for a 9-oz. box Product Snapshot: Kashi TLC Pita
Crisps are an all-natural snack made with Kashi’s unique combination of 7 whole grains, baked to toasty perfection into puffy crackers. Plus, each serving provides 10 g. of whole grains and 5 g. of fiber. They come in Original 7 Grain with Sea Salt, which boasts a combination of whole grains and cracked wheat berries with a sprinkling of natural sea salt, and Zesty Salsa, featuring a savory blend of herbs, spices and veggies, including onions, tomato, peppers and cilantro. Ingredients (Zesty Salsa): Wheat flour, Kashi Seven Whole Grains & Sesame flour (whole oats, hard red wheat, rye, brown rice, triticale, barley, buckwheat, sesame seeds), expellerpressed canola oil, cracked grain flour (rye flakes, wheat bran, stone-ground Ingredients (Chocolate Sandwich whole wheat flour, whole oats, barley Crème): Sugar, wheat flour, vegetable flakes, yellow corn meal, millet, brown oils (canola, palm, palm kernel, soybean, rice flour), oat fiber, chicory root fiber, partially hydrogenated cottonseed, coco- dried onion, sea salt, malt extract, nut), cocoa, dextrose, polydextrose, yel- evaporated cane juice, dried garlic, low corn flour, corn syrup, baking soda, dried yeast, dried tomato, spices, natural soy lecithin, salt, natural and artificial flavor, red bell pepper, cilantro extract, mixed tocopherols (for freshness), citric flavor, monoglycerides, vanilla extract. acid, non-fat dry milk, soy lecithin. Contains: wheat, soy, milk.
Company: Suncore Products, LLC, Denver, Colo. Website: www.whonucookies.com Introduced: July Distribution: National Suggested Retail: $2.99-3.49 for a 15.2-oz. box Product Snapshot: Who knew cookies could taste so good yet be so healthy? WhoNu? nutrition-rich cookies are packed with 20 essential vitamins and minerals, deliver 3 g. of fiber and contain 20% or more of the daily allowance of calcium, iron and vitamins A, C, E, D and B12. They come in Soft & Chewy Chocolate Chip, Crispy Chocolate Chip, Chocolate Sandwich Crème and Vanilla Sandwich Crème varieties.
Deep Dish Brownies
Company: Sanders Candy, Clinton Township, Mich. Website: www.sanderscandy.com Introduced: June Distribution: National Suggested Retail: $9.99 for a 22.1-oz. box of Fudge and 23.8-oz. box of Caramel Pecan and Peanut Butter Product Snapshot: Sanders Candy fused together pieces from its boxed chocolates and bits from its gourmet dessert toppings to create its deep-dish brownie line. Available in Chocolate Peanut Butter, Chocolate Fudge and Chocolate Caramel Pecan, these brownies consist of a rich brownie base, a layer of Sanders chocolate pieces, moist streusel topping and drizzled in gourmet dessert toppings. Each thaw-to-serve brownie is sold in an 8x8-in. pan and maintains a 9-month freezer shelf life. Ingredients (Chocolate Caramel Pecan): Sugar, enriched wheat flour bleached (flour, niacin, reduced iron, thiamine mononitrate, riboflavin, folic acid), corn syrup, partially hydrogenated vegetable oil (soybean and/or cottonseed), cocoa processed with alkali, cream, water, semi-sweet chocolate (sugar, chocolate liquor, cocoa butter, anhydrous milk fat, soy lecithin [an emulsifier], vanilla), milk chocolate (sugar, cocoa butter, milk, chocolate liquor, soy lecithin [an emulsifier], vanillin [an artificial flavor], vanilla), dried egg whites, milk, whey (milk), food starch modified (corn), non-fat milk powder, salt, leavening (baking soda, sodium aluminum phosphate, aluminum sulfate, monocalcium phosphate), dextrose, dried egg yolks, soy lecithin [an emulsifier], butter, wheat starch, pecans, invert sugar, citric acid, silicon dioxide, sodium sulfate, propylene glycol, mono and diesters with BHT, citric acid [for added preservatives], mono and diglycerides, sorbitan monostearate, polysorbate 60, cellulose gum, xanthan gum, polysorbate 80, glycerin, corn oil, beta carotene, caramel color, silicon dioxide, natural and artificial flavors, caramel color, red #40, alpha tocopherols [a preservative], carrageen, raisin juice concentrate.
Editor ’s Note: Go to www.snackandbakery.com to read about more new products. www.snackandbakery.com
August 2011 - Snack Food & Wholesale Bakery
31
The Nutritional Corner
Folic Acid Gets its Time to Shine nriched grains are a source of many key nutrients; one of the most noteworthy of these is folic acid. Folic acid is a B vitamin best known for its role in the prevention of some birth defects, but its benefits don’t stop there—several studies indicate the B vitamin can improve cognitive function and may help prevent heart disease and some cancers. The Food & Drug Administration (FDA), Washington, D.C., mandated folic acid fortification of enriched grains in the United States, starting in 1998 because of its role in the prevention of the neural tube defects spina bifida and anencephaly. As a result, enriched grains such as white bread, pasta and tortillas are the largest source of folic acid in the American diet; more importantly, the folic acid found in these foods has contributed to an approximate one-third reduction in the rate of birth defects in the United States. In addition, the Centers for Disease Control and Prevention (CDC), Washington, D.C., recently named folic acid fortification of enriched grains one of Top 10 public health achievements of the last decade,
E
32
Snack Food & Wholesale Bakery - August 2011
Judi Adams, president, Grain Foods Foundation and the Wheat Foods Council
The Centers for Disease Control and Prevention recently named folic acid fortification of enriched grains one of Top 10 public health achievements of the last decade, crediting these foods with a direct cost savings of $4.7 billion and 10,000 fewer birth defect-affected pregnancies. crediting these foods with a direct cost savings of $4.7 billion and 10,000 fewer birth defect-affected pregnancies. But the good news for folic acid doesn’t end there. Two recent studies further solidify the health benefits of the B vitamin. First, a study published in the July issue of the scientific journal Gastroenterology examined colorectal cancer rates since the government-mandated fortification of enriched grains began in 1998. This research was conducted in response to a handful of previous studies that called into question if consuming too much folic acid can increase the risk of developing colorectal cancer. To investigate this notion, researchers analyzed the food intake and colorectal cancer rates of nearly 100,000 men and women; interestingly enough, they found that rather than being a risk factor, the participants with the highest intake of folic acid were less likely to develop colorectal cancer, indicating folic acid can actually be protective against the disease. Secondly, research published in the July online issue of Pediatrics found that adolescents who ate a
diet rich in folic acid improved academic performance. Researchers found that of the 386 Swedish teens who participated, the students who regularly consumed adequate amounts of folic acid in their diets did better in school than those who did not. The researchers credit folic acid’s role in helping build DNA as the likely reason for this important benefit, which supports the need enriched grains in children’s diets. A large part of the Grain Foods Foundation’s outreach focuses on educating consumers on the health benefits associated with the fortification of enriched grains. We have shared news of the two recent studies via our social media channels and Daily Six blog. In further support, our “Bread Trail” public service announcement aimed at educating women of childbearing age about the importance of folic acid in the prevention of birth defects continues to air, reaching approximately 766 million viewers and exceeding $17 million in equivalent advertising value since its inception. The findings from the above studies and recognition from the CDC add to the wealth of information pointing to enriched grains’ well-deserved place in a healthful diet. I encourage everyone to share this great news through their personal and professional communication channels. SF&WB
www.snackandbakery.com
INSIDE: Industry Perspective TIA Show Info Exhibitor List & Map
Letter to the Industry Dear Members of the Tortilla Industry,
H
qualitechco.com 1-800-328-5870 ext. 219
proud sponsor of SF&WB’s
Tortilla Trends TT-2
Snack Food & Wholesale Bakery - August 2011
ow do you deliver an increasingly better product, year after year? The Tortilla Industry Association (TIA), Arlington, yet it has been comVa., is in its 22nd year, pletely sold out. And and tackles this chalthe entertainment this lenge every year on year is super as well. We behalf of its members. have arranged for three As we pass the halfcomedians and a singer. way mark of 2011, we In addition, the golf Jim Kabbani, chief executive officer completed what we’ve Tortilla Industry Association, Arlington, Va. tournament will be been told has been the held at the renowned best Tech Seminar ever, (which took place Rio Seco golf club on Sept. 11. The tournaMay 23-24 at Disney’s Grand Californian in ment will also have a special discounted Anaheim, Calif.), and is focused on making TIA rate. our upcoming TIA Convention the best ever as well. TIA serves and represents the We serve and represent the fastest fastest growing sector of the growing sector of the baking industry, with approximately $11 billion in estimated baking industry, with approxi2011 revenue and a double-digit growth mately $11 billion in estimated rate, which makes it even more important 2011 revenue and a double-digit that we meet our members’ needs. If you are not yet involved in the tortilla industry, growth rate, which makes it TIA invites you to share the passion and the even more important that we profits by joining us for the TIA Convenmeet our members’ needs. tion, Sept. 12-13 at the Caesars Palace, Las Vegas. Our events are designed to give attendees maximum exposure to all the This event, which was last year shifted latest in equipment, ingredients and soluto May as a way of accommodating the tions, all in one place through a two-day IBIE show co-location, has returned to its tradeshow exhibit hall, plus two half-days traditional timeframe. We are confident that of educational sessions. We also plan to give the 22nd annual TIA Convention is going to attendees ample opportunities to meet and be our best yet, and we hope that you will network with others in the industry. We make plans to come to the convention and want our members to have time to develop see for yourself. valuable new business and sales contacts. To register for this event and receive But what will make this year’s event updates or to learn more information, go to the best? For one thing, we have upgraded www.tortilla-info.com. the venue dramatically—for the first time, And to learn more about who is exthis year’s TIA Convention will be held hibiting, what to expect at the show, or to at the fabulous Caesars Palace on the Las hear about trends and new products from Vegas strip. We have arranged for specially various tortilla and flatbread producers, flip discounted room rates, which are selling out through the TIA pre-show coverage section fast. The exhibit hall is the largest ever, and of this issue.
TORTILLA TRENDS
An endless appetite for creativity and innovation. At QualiTech, we combine inventive ideas and technical expertise for an astounding array of stunning flavors, textures and colors of Pell-ettes, Flavor-ettes or customized bits. No matter what type of inclusion or delivery system you’re looking for, we’ll collaborate to create something amazing. Visit us at qualitechco.com or call 1-800-328-5870 ext. 219. ©2011 QualiTech
TIA Show Coverage
Touring the Tortilla Trade
T
he Tortilla Industry Association, Arlington, Va., presents the most important tortilla industry event of the year—the 22nd Annual Convention and Trade Exposition, which is scheduled for Sept. 12-13 at Caesar’s Palace in Las Vegas. Attendees can make the contacts needed to improve business and increase sales, see the latest in equipment, components, ingredients, packaging and systems, learn about new products and services and increase business and personal knowledge through seminars, training sessions and exhibits. Other networking opportunities involve TIA’s Annual Golf outing, set to take place at the Rio Seco Golf Course, a welcome reception and raffle, an entertainment banquet and an assortment of educational sessions. To exhibit, attend or to learn more information about the show, go to www.tortilla-info.com.
Convention Schedule Sept. 10 1-5 p.m.
Exhibitor Move-in and Registration, Ballroom 1-11
5-9 p.m.
Board Meeting
Sept. 11 Noon-6 p.m. 7-9:30 p.m.
Annual Golf Tournament, Rio Seco Golf Course Welcome Reception and Raffle, Forum 12-24
Sept. 12 8:30-9 a.m. 9-10:45 a.m.
Sponsored Session, Forum 12 Educational Sessions, Forum 12 11-11:45 a.m. Annual Meeting, including Hall of Fame Noon-5 p.m. Exhibit Hall Open 6:30-7:30 p.m. Reception, Forum 12-24
Sept. 13 8:30-9 a.m.
Sponsored Session, Forum 12
9-11:45 a.m.
Educational Sessions, Forum 12
Noon-4 p.m.
Exhibit Hall Open
Exhibit Hours
TT-4
Snack Food & Wholesale Bakery - August 2011
Monday, Sept. 12
Noon-5 p.m.
Tuesday, Sept. 13
Noon-4 p.m.
TORTILLA TRENDS
21st Century Grain Processing is a trademark of 21C Oats, Inc., a subsidiary of Viterra Inc.
Some of our best ideas come in small clusters. Creating the perfect oat cluster and coated whole grain ingredients to meet tigh t formula and final product specifications is only possible when your team is... creative. We work closely with our customers to ensure the perfect flavor and texture, every time. That’s unique. That’s essential. That’s how we roll. viterra.com/foodingredients
[email protected]
Exhibitor List & Map
ORGANIZATION
TT-6
BOOTH
ORGANIZATION
BOOTH
ORGANIZATION
BOOTH
02 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Danisco, USA . . . . . . . . . . . . . . . . . . . . . . . . . . 300
NUTEC Manufacturing . . . . . . . . . . . . . . . . . . 517
21st Century Grain Processing, a subsidiary of Viterra Inc. . . . . . . . . . . . . . 335
DSM Food Specialties . . . . . . . . . . . . . . . . . . 337
O’Mally Grain . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Fredman Bag. . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Packaging Progressions Inc. . . . . . . . . . . . . 235
AB Mauri Fleischmann’s . . . . . . . . . . . . . . . . 522
G&I Islas Industries. . . . . . . . . . . . . . . . . . . . . 425
Pendleton Flour Mills . . . . . . . . . . . . . . . . . . . 419
AFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Genpak. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Polyfirst Packaging, Inc. . . . . . . . . . . . . . . . . 302
Allied Blending & Ingredients, Inc. . . . . . . . 323
Glanbia Nutritionals . . . . . . . . . . . . . . . . . . . . 411
Quickdraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
AM Manufacturing . . . . . . . . . . . . . . . . . . . . . 331
Greenbelt Industries . . . . . . . . . . . . . . . . . . . . 524
Arr-Tech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Reiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Heat and Control . . . . . . . . . . . . . . . . . . . . . . . 307
Azteca Milling . . . . . . . . . . . . . . . . . . . . . . . . . 109
Innophos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Bagcraft Papercorn . . . . . . . . . . . . . . . . . . . . . 531
JC Ford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Baking & Snack . . . . . . . . . . . . . . . . . . . . . . . . 535
KB Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
Balchem Encapsulates . . . . . . . . . . . . . . . . . . 429
Kemin Food Technologies . . . . . . . . . . . . . . . 233
Bay State Milling Company . . . . . . . . . . . . . . 515
K-Tron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Bemis Company, Inc.. . . . . . . . . . . . . . . . . . . . 514
Kwik Lok Corporation . . . . . . . . . . . . . . . . . . . 315
Bolsas Delta S.A. De C.V. . . . . . . . . . . . . . . . . 513
Lawrence Equipment, Inc. . . . . . . . . . . . . . . . 119
Cambridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Miller Milling Company . . . . . . . . . . . . . . . . . 431
Thermo Fisher. . . . . . . . . . . . . . . . . . . . . . . . . . 520
Caravan Ingredients . . . . . . . . . . . . . . . . . . . . 129
Minsa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Thymly Products Inc.. . . . . . . . . . . . . . . . . . . . 418
Caremoli USA . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Mississippi Lime Company . . . . . . . . . . . . . . 410
TIC Gums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Casa Herrera. . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Moisttech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
United Bakery Equipment . . . . . . . . . . . . . . . 518
Chem-Mex Ind., Inc. . . . . . . . . . . . . . . . . . . . . 532
Molinos Anahuac Macsa . . . . . . . . . . . . . . . . 530
Urschell Laboratories, Inc. . . . . . . . . . . . . . . 421
Clabber Girl Corp. . . . . . . . . . . . . . . . . . . . . . . 415
Murzan, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Vista Solutions, Inc. . . . . . . . . . . . . . . . . . . . . 512
Corn Flour Producers, LLC . . . . . . . . . . . 311,313
NDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Wire Belt Company of America . . . . . . . . . . 229
Snack Food & Wholesale Bakery - August 2011
Roplast Industries Inc. . . . . . . . . . . . . . . . . . . 330 Rovey Seed Company, Inc. . . . . . . . . . . . . . . . 529 Sealed Air Corporation . . . . . . . . . . . . . . . . . . 519 Sheilds Bag & Printing Co. . . . . . . . . . . . . . . 511 Snack Food & Wholesale Bakery . . . . . . . . 408 SunOpta Ingredients Group . . . . . . . . . . . . . . 309 Taconic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
TORTILLA TRENDS
POWERFlex Long live the tortilla! ®
How flexible is your tortilla? Can you roll it, fold it, bend it and fill it full without it cracking? What about after 30, 60 or even 90 days? If you answered no to any of these questions, you need POWERFlex,® a revolutionary new enzyme/emulsifier blend containing G4 amylase enzyme from the baking experts at Danisco. POWERFlex® extends a tortilla’s freshness, shelf life and ability to handle processing and consumer use – even after 90 days! POWERFlex® puts new life back into your tortilla. Learn more by calling Janelle Crawford at 913-738-3421.
Telephone: (1) 800-255-6837 Fax: (1) 913-764-5407 www.danisco.com © 2011 Danisco USA Inc.
Thriving Tortillas This year, the tortilla market has had its share of ups and downs. But the market is rebounding, experiencing stronger growth, and is becoming one of the fastest growing segments in the baking industry, despite harsh weather and escalating commodities prices. Lauren R. Hartman, Editor-in-Chief
D
espite the rising prices of corn, due in large part to news related to energy supplies and the role of alternative fuels, the tortilla market is growing, and the taco shell is riding high, more popular than ever. Food producers are striving to expand the varieties of tortillas available on the market and have been introducing not only specially flavored varieties but also finished frozen foods incorporating tortillas, which cater to consumers who want more convenience or who are short on time. As U.S. consumers become more health-conscious and want healthier food choices, lower carbohydrate, higher protein and higher-fiber tortilla products are coming to the market. While the cost of commodities used in making tortillas has surged, Latinos have been largely responsible for a stronger share of consumer buying power in the United States, accounting for more than 9% of total buying power in 2009, compared to less than 4% in 1980, based on data estimates from market research publisher Packaged Facts. According to reports from the U.S. Census Bureau, the Hispanic population grew four times faster than the total population between 2000 and 2010. Hispanics’ buying power in 2010 exceeded $1 trillion, and the population includes a significant number of highincome households, according to Packaged Facts. With an estimated buying power of $616 billion, Latinos of Mexican heritage represent the single most influential segment of the Hispanic market. By 2015, Packaged Facts forecasts that the buying power of the Latino population as a whole will reach $1.3 trillion. But, tortillas are also being consumed more and more by
Photo courtesy of Don Pancho Authentic Mexican Foods
non-Hispanic consumers, thus fueling the highenergy growth. Hurried consumers continue to consume fast foods of which a major segment is Mexican food. “While there is a great deal of disagreement regarding the economy, including the nature and extent of any recovery from the recession, the trends are very clear in one sector: The tortilla industry has grown from $6 billion a year just a few years ago to an estimated $11 billion by the end of this year., says Jim Kabbani, chief executive officer of the Tortilla Industry Association (TIA), Arlington, Va.
Buying locally or ‘at the deli’ This year, tortilla marketers and manufacturers rolled out new products developed to cater to a healthier lifestyle with whole wheat, lowerfat and high-fiber offerings, as well as products that cater to the non-Hispanic sector. A visit to the Big Apple inspired Blue Marble Brands, Providence, R.I., to launch a Tumaro’s line of New York Deli Style wraps, inspired by the flavors abundant in New York’s legendary delis. And while deli foods aren’t often associated with better-for-you benefits, the five varieties—Rye, Pumper-
Photo courtesy of French Meadow Bakery
TT-8
Snack Food & Wholesale Bakery - August 2011
nickel, Sour Dough, Everything and Cracked Pepper—offer bold, authentic wrap flavors common with gourmet deli bread. Plus, these 10-in. wraps are is 96% fat-free, cholesterolfree, high in fiber and deliver 100 calories or less, says the company. “We love the bread and bagels we find in New York delis, so we wanted to create a line for Tumaro’s that delivers those classic varieties in a convenient, wholesome wrap,” says Chris Test, president of Blue Marble Brands. “Packed with fiber…the New York Deli Style Wraps are true to the original breads while helping our customers maintain a healthy lifestyle.” According to Testa, Tumaro’s was the first brand to introduce flavored tortillas to the market, including Jalapeño & Cilantro, Rosemary & Olive Oil and Roasted Red Pepper. Blue Marble also produces 8-in. flavored tortillas, 10-in. wraps, soy-full Heart Tortillas and low-carb versions, boasting zero transfat and cholesterol-free label claims and are kosher certified. Blue Marble’s packaging also is changing, Testa adds, because the company wants Tumaro’s to be the primary choice for the healthy, discerning consumer. “We want to draw attention to the benefits Tumaro’s has,” he says. Despite all of the varieties, Testa insists that flavors aren’t changing. “We continue to define ourselves by innovation with the New York Deli Style Wraps. We’ve seen more and more competitors adopt these same flavors, but they aren’t really anything new or innovative. “In general, the sales of standard tortillas— basic corn or flour tortillas—are flat,” Testa admits. “Some companies are playing a value game, simply selling the most tortillas for the least amount of value. Although they have massive volume, sales are flat. It’s a billion dollar category, so certainly tortillas have become mainstream. Products that are multigrain, lowcarb, functional, gluten-free, etc., are really raising the bar on innovation and health.” Continued on page TT-10
TORTILLA TRENDS
Process. Package. Prosper!
Get more machinery, for more corn products from one source you can always rely on. Heat and Control will help you profit with efficient machinery for all types of corn snacks, tortillas, tostados, taco shells, and prepared frozen foods. We supply equipment designed specifically for your products, operations, and sustainability. And we support you from start to future with sales, installation, service, parts, and training. Contact Heat and Control today to discuss your next project and see demonstrations of our latest equipment. • Corn cooking & masa preparation • Sheeters & extruders • Conditioners, fryers, ovens, coolers • Seasoning applicators • Ishida multihead weighers • Ishida snack bagmakers • Ishida checkweighers, X-ray inspection, bag seal checkers • CEIA metal detectors • Conveyors, accumulators, distribution systems • Container fillers, tray sealers • Packaging platforms • Real-time line management & control systems
See us at Pack Expo Las Vegas Booth C-2433
One Call Delivers 800 227 5980
www.heatandcontrol.com
Continued from page TT-8
He says that Blue Marble is consumerdriven company that wants each of its brands to reflect what’s going on in a consumer’s mind. “Tortillas and wraps have been an alternative for sliced bread and rolls for years. Now that the market is becoming more mature, con-
sumers are raising the bar. Having gluten-free options or having the Whole Grains Council certify tortillas, or offering multigrain, low-carb products or products made with flaxseed, are in response to consumers asking for more healthy benefits from their tortillas and wraps.” Blue Marble’s biggest challenge is merchan-
dising, Testa says. “The tortilla category was developed in the ethnic, TexMex section. As consumers look for bread alternatives, they are not shopping that aisle. Our challenge is to get our products placed in the deli area or in a secondary display. Our New York Deli Style Wrap line belongs in the deli aisle. It doesn’t [belong] below in the taco section. That’s our biggest challenge.”
Going mainstream?
;Xl\i_X]k ;liX[\if ;liXklif ;li}m\c
;liXYc\ No matter how you say it... We’re tough!
T
aconic’s non-stick tortilla belts
are tough enough to stand up to anything you can dish out. With our high performance belts, you’ll watch your belt changeovers go down while
;liXYc\ Fgk`dXcI\c\Xj\ K\dg\iXkli\I\j`jkXek F`c&>i\Xj\I\j`jkXek GleZkli\I\j`jkXek =fijkXe[Xi[Xe[ZljkfdY\ckjn`k_mXi`flj jgc`Z\fgk`fej#ZXccKXZfe`ZXk1
($/''$/*)$'0/) 8]XYi`ZefkZ_jgc`Z\ \c`d`eXk\jk_\d\kXc Zc`g%@klj\jXi\`e]fiZ\[ dXk\i`Xcn`k_Xjg\Z`Xc g`e]fiaf`e`e^%
=XYi`ZEfkZ_Jgc`Z\
your productivity goes up. And that’s a tough act to follow!
nnn%+kXZfe`Z%Zfd
French Meadow Bakery, Minneapolis, disagrees with the tortilla market being flat. “It’s experiencing tremendous growth during the past year,” says Emily Dingmann, marketing coordinator. “The market is now a mainstream consumer product expectation. In response, French Meadow Bakery is pleased to offer gluten-free tortillas and sprouted grain tortillas for consumers. Traditional corn and flour tortillas have been in demand for many years, but now consumers are expecting a wider variety of grains incorporated into products. We have experienced an extremely positive reception to both our gluten-free tortillas and sprouted grain tortillas.” Both products are two of the most versatile products French Meadow offers. Dingmann says some of the consumer trends driving such growth in the tortilla market are certain dietary needs and the gluten-free surge. “Today, those with specific dietary needs are able to enjoy tortillas and all of the many ways they can be incorporated into a nutritious diet,” she says. “Our tortilla tastes like traditional flour tortillas.” Additionally, Jerry Chizick, vice president and general manager of Handi Foods Ltd., a Canadian baker of Mediterranean fresh, frozen and double-baked snack foods and baked goods such as pita products, crisps, pita bagels, flatbreads, pizza crusts, crackers, pita chips and more, agrees that tortillas are going mainstream. “It’s happening. Some of the new trends are developing in the tortilla market because the Hispanic population is growing nationally,” he says. “Flavors and ingredients are changing—some more ethnic ingredients and some that are being used because of growing nutritional concerns. As tortillas become more mainstream, non-Hispanics are finding new uses. Much like the bagel, which was more ethnic years ago, several varieties have come into being to cater to the mass market.” Continued on page TT-12
TT-10
Snack Food & Wholesale Bakery - August 2011
TORTILLA TRENDS
Continued from page TT-10
Wheat is still one of the best values of nutrition, Chizick says. “And we expect the number of whole-grain [products] to continue to increase. We are also testing low-sodium product developments. Breads are a low-cost staple and consumers get a good degree of their sodium from bread due to the volume consumed. So several bakers are trying to reduce sodium.” Shelf life has become a real issue, he says particularly with respect to global warming, which causes products to mold faster. “And regulations are creating significant challenges for smaller operations, which find it difficult to keep up and manage or risk being left out of the market. Those are our biggest challenges. But we think flatbreads are gaining in popularity as a low-cost option,” Chizick adds. At Don Pancho Authentic Mexican Foods, Salem, Ore., president Ricardo Baez says that he doesn’t feel tortillas have become a weekly staple in the non-Hispanic shopping basket, but are certainly becoming an increased option due to their versatility at home. “With the increased demand for whole-grain products, I can see tortillas becoming a true, mainstream option in this country,” he states. New trends in the tortilla market closely follow what’s happening in the bread industry, Baez says. “There is a tremendous emphasis in developing tortillas that have a higher nutritional content, lower sodium and more fiber, that still taste great. Snack and bakery tortillas are following along t he same lines as [bread] with multigrain, ancient grains, high fiber and low sodium. We work with bakery products in tortillas and have a fried chip line to incorporate these two applications.” Baez agrees that flavors in the category are changing. “And ingredients are also changing to reflect the fact that tortillas are a universal carrier of great food from around the world,” he adds. “We now have new flavors such as curry, Italian Parmesan, blue cheese, cheesy jalapeño, Roma Tomato, Wasabi and Ranch-flavored wraps amongst others.” Don Pancho’s lineup of new products use the tortilla as a carrier for food from around the world. The company developed a line of exotic flavors with reduced sodium to meet this demand. It also has a family of tortillas sold at retail that feature lower sodium and lower calories with additional pliability and flexibility. For whole-grain enthusiasts, there are items such ancient grain and multigrain tortilla wraps with lower sodium, high fiber and “a wonderful array of good-for-you ingredients,” according to Baez.
Bright future in the bread aisle “Tortillas and flatbread have a bright future in the bread aisle…Consumers are looking not only to purchase a great-tasting tortilla, but to use tortillas as a way to incorporate additional nutrition to their diets, and make burrit os, quesadillas, sandwich wraps, tacos, pita sandwiches, flatbread sandwiches or snacks,” Baez says. “We introduced a gluten-free tortilla to recognize this market. It will take time to develop this niche market, and distribution will be a key to success in the gluten-free category. There is tremendous interest in multigrain tortillas, ancient grain tortillas, low-sodium tortillas, hi gh-fiber tortillas and reduced-calorie tortillas.” Don Pancho also developed a line of low-sodium tortillas with a reduced calorie content that will roll to market soon, and is redesigning its packaging to reflect the added benefits of the ingredients in the tortillas. Baez points to the issues of food safety, traceability, recall programs, ingredient declarations and other factors that contribute to the tortilla industry’s biggest challenges and opportunities. “It’s important to ensure that all of the folks involved, from suppliers to distributors, understand that it is our col lective responsibility to provide a product that is safe to our consumers,” he says. “Shelf life has been and always will be important in the tortilla industry. We need to manufacture and distribute a product that will provide the consumer a wonderful experience. Ingredients are being developed to extend shelf l ife Continued on page TT-14
TORTILLA TRENDS
Up Coming Shows
͚͙͙͘ ǣ͙͚Ǧ͙͜
In A Competitive Market You Need....
.....Time-Tested Dependability & Performance
Over the last 28 years Arr-Tech has been the leader in the manufacturing of the most versatile and reliable automated counting, stacking, and packaging machinery for the bakery industries. No matter if your lines are new, used or combinations of each, Arr-Tech systems can be integrated with any and all manufacturer’s of bakery production lines. Arr-Tech can design a
Ƥ
Ǩ
Ǧ Ǥ
Ȉ
Ǧ and to help manage the production process through detailed and automated reporting Improve Quality, Reduce Waste, Reduce Cost, and Increase Competitiveness Ȉǡ
ȈǡǦ
bagging and wrapping
Ȉ
Ȉ
ǡ
ǡ ǡ ƪ ǡ
ǡ ƫǡ
Ǧ
Ǧ
Ǧ
Ǧ
ǡ
ǡ
ǤǡǦ
Ǩ
͞ Ǧ
ǡ
Ǥ ͘͞
Ǧ
ǡ
Ǥ ͙͛͘͠ǤȈ ǡ͛͘͡͠͡ ͠͞͞Ǥ͚͠͝Ǥ͚͚͜͜Ȉ ͘͝͡Ǥ͚͜͝Ǥ͙͛͟͜ȈǦ
Ǥ
Continued from page TT-12
and on the equipment side, our equipment suppliers are building equipment that is easier to clean and with better materials. And just as important, the continued training of staff to ensure equipment is always clean, well maintained and always making sure we follow
good manufacturing practices.” Nearly every home purchases tortillas, says Greg Bingham, vice president of Don Julio Foods Inc./Clover Club Foods, Clearfield, Utah, which produces tortillas, chips and salsas as well as snack foods, flour tortilla chips and dips. “Their use extends beyond
just enchiladas, tacos and burritos. Organic and better-for-you tortillas are becoming a fast trend. More aggressive promotional price points are driven by the increasing number of brands available, as well as the economy.” Considering the white flour tortilla as the prime driver of the entire category, Don Julio is launching uncooked flour tortillas with a fresh, made-in-your-kitchen taste in both regular flour and whole-wheat varieties. “But a big consumer trend is ‘fresh’ product,” he notes.
See us at TIA booth #135
FLOUR TORTILLA High capacity flour tortilla lines utilize continuous press technology to produce up to 2200 dozen tortillas per hour.
CORN TORTILLA Automatic corn tortilla systems with production capacities up to 7000 dozen per hour. The standard of the industry!
“Other consumer requests we hear about include the need for low-sodium, whole-wheat and multigrain varieties, which we are taking seriously. The new uncooked products require a thicker, denser barrier for freshness. The cost is higher but quality improvement is increased substantially.” Don Julio continues to improve its production operations by upgrading metal detection and sifting equipment and with electronic quality control equipment that controls the size uniformity, color and shape of its products resulting is very high quality, Bingham says. “We continue to conduct consumer research, which indicates interest in whole grains. We plan to introduce whole-grain products in the near future.”
Innovation and freshness are key
TORTILLA CHIPS Tortilla Chip systems ranging from 500 pound per hour to 4000 pound per hour. From masa flour handling or complete corn cooking systems to seasoning and packaging JC Ford can handle all of your production needs.
JC FORD With 65 years in the tortilla production industry, we offer the latest in corn and flour tortilla production equipment.
Joe Rabaglia, vice president of marketing at Azteca Foods, Chicago, thinks the tortilla market is under heavy pressure from other bread alternatives, especially flatbreads, fighting for share of the eating occasion. “Tortillas have become more mainstream, driven by restaurants offering tortillas as a carrier for non-traditional Mexican recipes (breakfast burritos, wraps etc.). The increase in the number of retail grocers offering private-label/store brand tortillas is another strong indication of the mainstreaming of tortillas. So innovation will be the key for tortilla growth. This can come in the form of new shapes, healthier offerings and bold flavors. Consumer preference for flavors and ingredients is a dynamic, not a static, process. As tortilla manufacturers, we need to be in tune with consumer trends and offer tortilla products that are consistent with consumer trends.” The snack category also plays a major role, Continued on page TT-16
TT-14
Snack Food & Wholesale Bakery - August 2011
TORTILLA TRENDS
solutions
for freshness & functionality See us at TIA Booth #129
food, bakery & nutrit bout our a e r o m n r a To le
ional ingredients, call 800.669
.4092
Innovative tortillas Anti-stick, extended shelf life, flexibility & clean label solutions Full scale R&D department enables internal validation of new products, increasing your speed to market Our tortilla experts will work with you to create optimum products for your facility SERVICE AND TECHNOLOGY WORKING FOR YOU www.caravaningredients.com
Continued from page TT-14
he points out. “There has been a proliferation of frozen snacks that utilize tortillas as the carrier/holder,” Rabaglia says. “We are exploring new products that add value and address their needs. I don’t want to get more specific than this. But the trend that currently has the biggest impact on consumption is the economy.” Azteca produces refrigerated tortilla products, while emphasizing freshness and efficacy. “Freshness and efficacy are extremely important attributes consumers require from a tortilla. Extending the shelf life at the expense of product freshness and efficacy is a trade-off that we will not be willing to make,” Rabaglia says.
Changing the ways we eat The increasing Hispanic population and the influence it has on our society, culture and behavior is certainly a driving force of the growth of the tortilla market, says Raymond Gunn, owner and CEO of MexAmerica, St. Marys, Pa., which produces a variety of fresh flour and wheat tortillas and wraps, including gluten-free, trans-fat-free products as well as a select line of corn tortillas and related chips. The products are generally sold fresh in the
dairy case, and carry a 90-day shelf life. What’s making the tortilla market tick? “It’s the influence from the increasing Hispanic population that’s driving awareness and developing the demand for tortilla and other Hispanic-based products,” Gunn says. Wraps and tortillas beg consumers to be creative, Gunn says. “It’s the wraps and non-traditional ways to make sandwiches that’s interesting. The ability to put content into a tortilla and roll it or fold it in a way that cannot be done with typical bread slices is creating whole new ways to eat our favorite. “We stick to a very narrow product line of excellent fresh tortilla products using the finest ingredients, so we avoid chasing the latest fads,” he adds. However, MexAmerica does keep watch on various new twists to see if they are more than fads. Currently the wholewheat, honey and select other flavors seem to be consumer favorites, so we focus on those flavors and use the very best, fresh ingredients to differentiate our brand from the volume commodity players.” Gluten-free products are gaining more interest, obviously driven by the increasing awareness of celiac disease. “We view this as
an important development and are watching it closely,” Gunn says. “We were one of the first consumer brands to introduce gluten-free corn tortillas and to develop the awareness. We are watching this market and will respond accordingly as we see the need unfold.” Gunn observes, “We also see whole grain as a growing trend that we hope to capitalize on.” Gunn describing his company as customercentric. “We talk regularly to our food brokers, store buyers, distributors and attend shows, read the various industry journals and internet blogs. We are launching a more aggressive sales and marketing program for 2012 and are looking to penetrate deeper into existing markets, then move into the Midwest and Southeast as we utilize our additional production capabilities in Michigan and New Jersey.” New packaging may be on the horizon, as the company is exploring this along with its plant expansion plans. Don’t be surprised if there’s a large expansion in tortillas and flatbreads to accommodate changing consumer tastes. “Tortillas certainly deserve a seat at the table with bread as a main player in the bread aisle today and tomorrow,” Baez sums up. SF&WB
Quick, On-Time High Quality Tortilla Bags Let us solve your supply line problems. We are proud suppliers to the American Tortilla Industry for over 20 years. Custom printed, with or without zipper, packed loose or on wickets/staplepacks. All made here at our facility in Oroville, California.
3155 South 5th Avenue Oroville, CA 95965 800.767.5278 WWW.ROPLAST.COM
TT-16
Snack Food & Wholesale Bakery - August 2011
TORTILLA TRENDS
Compact Grid™ conveyor belt… only from Wire Belt.
The BEST belt for tortilla chip lines! t4VQFSJPSTVQQPSUUPSUJMMBDIJQT t 70% open areaBMMPXTGPSNPSF FGmDJFOUGSZJOHBOEDPPMJOH t#FMUKPJOJOHJT'"45BOE4*.1-& t-PXFOFSHZSFRVJSFNFOUGPSPQFSBUJPO t&YDFMMFOUCFMUUSBDLJOH t&BTZUPSFUSPmUPOZPVSDPOWFZPS t64%""DDFQUFE &BTZUPDMFBO SEE US AT THE TIA SHOW! Sept 12-13, Booth 229 Caesar Palace, Las Vegas NV Wire Belt Companyt)BSWFZ3PBE -POEPOEFSSZ /) 5&-t'"9 &NBJMTBMFT!XJSFCFMUDPNt8FCTJUFXXXXJSFCFMUDPN *403FHJTUFSFE$PNQBOZ
Heat and Control Booth # 307 One call to Heat and Control delivers complete processing, inspection, product handling and packaging equipment systems for producing corn and tortilla chips, extruded and pellet snacks, taco shells, tostadas and corn tortillas. Its product line and services include: • Corn cooking and masa preparation • Sheeters, ovens, extruders and fryer systems • Seasoning application • Conveyors and product distribution • Ishida weighers and bagmakers • Ishida checkweighers and x-ray inspection • Ishida tray sealers • CEIA metal detectors • Control systems integration and MES platforms • Sales, service and parts • Equipment demonstrations • Processing and packaging training Heat and Control Hayward, Calif. 800-227-5980 www.heatandcontrol.com
Taconic Booth # 321 Taconic’s nonstick tortilla belts are tough enough to stand up to just about anything. Offering durability, optimal release and resistance to oil/grease penetration, high temperatures and punctures, Taconic’s high-performance belts increase productivity by reducing the need for belt changeovers. Taconic provides standard and custom belts with a variety of splice options, including a fabric notch splice, which eliminates the metal clip, utilizing a reinforced material with a special pin for joining. With 50 years of industry experience, Taconic is a leader in nonstick belt, fabric and tape technology. Serving the international marketplace with corporate facilities around the globe and a multilingual engineering and sales network, Taconic is ready to troubleshoot any application and provide the solution to any processing need. Taconic Santa Maria, Calif. 800-832-0982 www.4taconic.com
Arr-Tech, Inc. Booth # 301 Over the last 28 years, Arr-Tech has the most versatile and reliable automated counting, stacking and packing machinery for the baking industry. All Arr-Tech systems are modular in design, allowing for a customized system to fit within each packaging area. In addition, ArrTech offers multi-functional integrated packaging systems, including: • Vision inspection/rejection systems—a tool to provide information on and to help manage the production process through detailed and automated reporting, improving quality, reducing waste, reducing cost and increasing competitiveness • Bagging, wrapping or our multi-functional dual system for both bagging and wrapping • Inline bag sealing as well as other package closure systems • Case erecting and sealing systems Whether your products are tortillas, frozen waffles or pancakes, pizza crusts, pita or flatbreads, Arr-Tech certifies that adding a timetested Arr-Tech automation system will improve the bottom line. Arr-Tech, Inc. Yakima, Wash. 866-852-2442 www.arr-tech.com
Kwik Lok Corp. Booth # 315 Kwik Lok Corp. was founded in 1954 by Floyd Paxton when he invented that “funny little plastic clip.” Known as a Kwik Lok, th e clip was developed to provide a fast, simple solution to quickly closing apple bags on hand-bagging lines. Today, the plastic clip offers even more. Kwik Lok has addressed traceability and recall concerns by offering a wide range of printing options, including cold foil, laser, ink and thermal transfer solutions. Each option presents a wide range of printing capabilities to include real-time display, 2D bar codes, best-before dating and plant code information, all available in one consistent easy-to-read location. Kwik Lok Corp. Yakima, Wash. 800-688-5945 www.kwiklok.com
ADVERTORIAL
TORTILLA TRENDS
Continued on page TT-20
August 2011 - Snack Food & Wholesale Bakery
TT-19
Minsa Corp. Booth # 105 Caravan Ingredients Booth # 129 Caravan Ingredients is a leader in the finest quality bakery and food ingredients. For 108 years, it has delivered innovative solutions, technical expertise and endless customer service. Its wide product range includes industrial and artisan baking products and ingredients for tortillas and flatbreads, as well as food ingredients, flour additives and polymer additives. At TIA 2011, Caravan’s tortilla experts will be available to discuss the new Basic Tortilla 3, Southern Tortilla, Carasalt Tortilla and Tortilla Suave products. Each provides a unique solution to tortilla manufacturers, such as easily customizable bases for adding flavor inclusions and reduced sodium, anti-stick and extended shelf life technology, all while maintaining soft, pliable tortillas. Caravan Ingredients Lenexa, Kan. 800-669-4092 www.caravaningredients.com
NuTEC Manufacturing Booth # 517 For NuTEC Manufacturing, what began 26 years ago with a simple hamburger patty forming machine, has grown to a product lineup that includes six different food formers with varying capacities, C-frame portioning depositors for dough-enrobed or filled products and an automatic direct depositing and tray indexing conveyor. In 2010, NuTEC introduced the tray indexing conveyor, which is configured to run with NuTEC’s 720 forming machine. When set up with the 720, the tray indexing conveyor efficiently portions and deposits fillings directly onto tortillas at speeds of up to 65 tortillas per minute. NuTEC Manufacturing New Lenox, Ill. 815-722-2800 www.nutecmfg.com
Minsa Corp. is a pioneer and one of the leaders in corn masa flour production. For more than 60 years, Minsa has prevailed as an authentic supplier for the tortilla and snack industries. Minsa strives for the satisfaction of its customers and endconsumers by offering more than 50 different products, including conventional, non-GMO and organic corn masa flour that is whole-grain and gluten-free certified. Minsa also offers certified white, yellow, blue, purple and even red flours that abide by strict protocols of good manufacturing practices and quality assurance. Minsa introduces Soulmaize, an innovative and healthy alternative for the bakery industry. Its full line of premixes is designed for pancakes, muffins, pizza crust and other bakery applications. Minsa not only offers the best quality products and wide variety, but also provides the best service, technical support, research and development and competitive advantages for your operation. Minsa Corp. 800-852-8291 www.minsa.com
Wire Belt Co. of America Booth # 229 Wire Belt offers the latest in metal conveyor belt solutions for the tortilla industry, including TC-327 belt for cooling tortillas and CompactGrid for chips and snacks. Made of stainless steel, these belts don’t sweat, slip, droop, sag or catch fire on systems like many plastic conveyor belts can. Engineered to cool tortillas, Wire Belt guarantees a two-year belt life for TC-327. And, the open design of CompactGrid makes it the ideal solution for cooling freshly baked or freshly fried products in high-volume, high-throughput processes. Wire Belt Co. of America Londonderry, N.H. 603-644-2500 www.wirebelt.com
ADVERTORIAL
TT-20
Snack Food & Wholesale Bakery - August 2011
Continued on page TT-22
TORTILLA TRENDS
AM Manufacturing Co. Booth # 418
Roplast Industries, Inc. Booth # 330 Roplast Industries, Oroville, Calif., is an integrated manufacturer of low-density polyethylene film and bags. Since 1990, it has extruded film, printed and converted bags for tortillas and many other applications. Roplast is leader when it comes to print and bag quality, ontime delivery and customer service, and has proven valuable to its customers in order for them to avoid supply disruptions. Roplast strives to establish a partnership with its customers. It assists with creation of artwork from the initial sketch to the final layout, and offers stocking arrangements at its own facility, all at competitive pricing. Roplast Industries, Inc. Oroville, Calif. 800-767-5278 www.roplast.com
Since 1961, AM Manufacturing has been a leader in dough processing equipment. Located in Dolton, Ill., a southern suburb of Chicago, AM Manufacturing produces dough dividers, dough rounders, pizza/tortilla presses, pizza crust dockers, proofers, cooling conveyors and bagel forming equipment, and maintains the expertise to design entire pizza, tortilla and bakery lines. AM Manufacturing Co. Dolton, Ill. 708-841-0959 www.ammfg.com
Danisco USA Booth # 2011 The simple way to a perfect tortilla starts with ingredient technology from the experts at Danisco. Danisco’s POWERFlex solutions for flour and corn tortillas bring together the company’s leading ingredients and application expertise to fit all expectations of delicious tortilla products, including softness and flexibility, efficient production, reduced stickiness and stay-fresh quality. Danisco USA Inc. New Century, Mo. 913-764-8100 www.danisco.com
21st Century Grain Processing Booth # 335 Leading food manufacturers trust the Viterra brand to provide quality ingredients, strategic partnerships and technical expertise. 21st Century Grain Processing brings a business partnering approach to every relationship by collaborating and consulting with customers to drive continuous improvement. Already a leader in oats, barley, malt and canola oil, the Viterra lineup now offers Panhandle Milling wheat flour and custom-coated whole grain and granola clusters. Panhandle Milling flour products are the choice of certified bakers when excellence in baked products is required. Its team works passionately with customers to consistently deliver the highest quality product, flavor and texture every time. It also stays involved every step of the way to ensure precise delivery to meet your baking and tortilla needs. 21st Century Grain Processing Kansas City, Mo. 806-258-7253 www.viterra.com/foodingredients
Allied Blending & Ingredients, Inc. Booth # 323-325, 422-424 Allied Blending offers a complete line of ingredients, liquid and dry blends and preservatives for both corn and flour tortillas. The line of BatchPaks offers unbeatable consistency, ease of use when making table tortillas and special formulas for low-carb or reduced-sodium wraps. Allied’s family of Especial liquid preservatives extend the shelf life of corn tortillas from 3090 days. Allied Blending is the one-stop solution provider for all of your functional tortilla ingredient needs. Allied Blending & Ingredients, Inc. Keokuk, Iowa 800-758-4080 www.alliedblending.com
ADVERTORIAL
TT-22
Snack Food & Wholesale Bakery - August 2011
TORTILLA TRENDS
The Best Tortillas Start with Allied Blending
Allied Blending & Ingredients’ custom and pre-blended formulations make baking the freshest tortillas easy. Our application processing expertise and exceptional technical support make your operation a success everytime. High-Performance Products
Technical Capabilities:
Tortilla BatchPak™ Formulations: Low Sodium Gluten Free Heart Healthy Multi-grain 100 Calorie Low Carb Whole Wheat Low Fat
BatchPak™ delivery systems ensure consistency and control costs Liquid and dry preservative systems for all your tortilla needs Custom formulations and on-site technical service to meet your specific requirements Bake lab facilities and commercial grade tortilla manufacturing unit for continuous Quality Assurance and Product Development Innovative formulations, including clean label, trans fat free and organic Computer-aided dosing systems to ensure blending accuracy for critical ingredients
www.alliedblending.cOM s © 2011 Allied Blending & Ingredients. All rights reserved.
Ingredient Technology Fats & Oils
Spread the Word About New Fats and Oils Many ingredient suppliers provide a wealth of fats and oils that deliver on taste, texture and functionality, all while significantly lowering fat content. Here’s a peek at some of the products allowing bakers and snack producers to reformulate their products and provide healthier options. Lauren R. Hartman, Editor-in-Chief
n the food industry, fats and oils must deal (unfairly) with bad press at times, and with health issues so important today, there is quite a bit of press coverage relating to fats and oils. The general consensus may be that all fats and oils are created equal, but all fats and oils have their own fatty acid profile and are good for different applications. And, fats and oils are important ingredients for snack and bakery products because they provide the stability needed for processing and an increased shelf life. Consumers are seeking snacks and baked goods with less saturated fat, which obviously bears the brunt of the negativity, as findings highlight its less-than-healthy aspects. The 2010 Dietary Guidelines for Americans call for an overall reduction in saturated fat intake, replaced by monounsaturated and polyunsaturated fats, to decrease risk of cardiovascular disease. According to Dow Agrosciences, consumers now realize the impact that “bad,” trans fat and saturated fats have on their diet and long-term health. Thus, consumers are looking for healthier oils now more than ever.
I
The other Omega In the 2010 Gallup Study on “Healthy Fats & Oils,” adults are making about the same amount of effort to include healthy fats and oils in their diet (58%) as they are to
exclude unhealthy ones (61%). That’s why Dow Agrosciences developed what it believes is the first saturated fat-free oil product. Called Omega-9 Sunflower Oil, the product could be a gamechanger for many food manufacturers, the Indianapolis-based company says. Dow AgroSciences unveiled the oil at the Institute of Food Technologists (IFT) Annual Meeting and Food Expo in New Orleans, June 11-14. For food manufacturers seeking solutions to meet increasing customer demand for healthier products, Omega-9 Sunflower Oil is one of the healthiest oils available, says David Dzisiak, commercial leader of grains and oils. “The oil also has zero trans-fats and is uniquely high in heart-healthy monounsaturated fats,” he says. With Omega-9 Sunflower Oil, companies can significantly reduce or eliminate saturated fat from new front-of-pack labels, which will begin to appear on retail shelves within the next two years. “Omega-9 Sunflower Oil provides a very powerful ingredient advantage for food manufacturers, potentially allowing them to eliminate saturated fat from food products by making the switch,” says Dzisiak. Recent concept research found consumers preferred a saturated fat-free label claim on a retail bottle of oil 5:1 over the same product labeled without the claim, he says. “This can truly impact purchasing behavior at the grocery store. It’s pretty amazing to offer an oil that’s virtually all ‘good’ fat.”
Photo courtesy of Dow AgroSciences
Omega-9 Sunflower Oil is all natural and can support an all-natural package claim, the company says. The oil comes from NEXERA seeds developed by Dow AgroSciences through traditional plant-breeding. Because the oil has a very high level of stability, many formulations will not require antioxidants, TBHQ or partial hydrogenation to achieve the desired shelf life. Dzisiak says that while the public has become increasingly aware of the health benefits of Omega-3 fatty acids and now Omega-6 fatty acids, the other key player is Omega-9 fatty acids. Omega-9 oils ingredient solutions also improve flavor, shelf life, texture and mouthfeel while improving the health profile,” Dzisiak adds. “The new applications provide ‘cleaner’ ingredient laContinued on page 58
www.snackandbakery.com
August 2011 - Snack Food & Wholesale Bakery
57
Ingredient Technology Photo courtesy of Advanta Semillas SAIC
Continued from page 57
bels because Omega-9 oils and shortening formulations are naturally stable. Without a need for antioxidants, tertiary butylhydroquinone (TBHQ) or partial-hydrogenation in order to achieve appropriate shelf life, this stability allows for a simpler ingredient list that food manufacturers and consumers alike can feel good about.” Advanta Semillas SAIC in Buenos Aires, Argentina, also promotes sunflower oil as an alternative to conventional oils. Nutrisun high-stearic, high-oleic sunflower oil is stable and functional as well as palatable and meets the needs of the healthy segment for several applications such as bakery, frying, confectionery and as a cocoa butter replacer, among others, says Lucas Pan, fats and oils leader, Nutrisun Business Unit at Advanta. “Compared to sunflower oil, Nutrisun and high-oleic sunflower oil, canola oil, cotton oil and low-linolenic soybean oil, Nutrisun is a much more stable product regarding oxidation,” he says. “The product itself and as an ingredient of the final product, Nutrisun, extends shelf life. There are some cases such as when incorporated to doughs were we have also been able to detect an interesting lubrication function. When used in frying, oil uptake is lower, therefore we avoid an oily final product that doesn’t usually meet customer expectations on how the product should look and taste.” Other trends Pan notices are sustainable practices, which have been observed by Advanta. “They are key to eco-friendly production of Nutrisun,” he says. The most popular fats and oils right now, depending on the application, are hydrogenated vegetable oils or palm oil for shortenings and hydrogenated soybean oil, cottonseed and sunflower oils for frying, as well as canola oils and palm olein. “The new trends include modified oils, such as mid- and high oleic-, high-stearic high-oleic sunflower oil, low-linolenic soybean oil and shortenings based in hydrogenation and interesterification,” he says [Note: Enzymatic interesterification is a modification technique used to produce low trans-fat shortening].
Clean labels clean up Cleaner nutrition labels with recognizable ingredients are high in demand as well. “To compete, bakers and producers may need to take a look at their ingredient lineup, including the use of antioxidants and preservatives,” Dzisiak continues. Additionally, there are challenges in formulating new fats and oils products such as rancidity, which affects flavor and can increase free radical formation. When formulating with Omegas, challenging factors include off-flavors, instability, rancidity and oxidation, Dzisiak points out.
Health is key Jim Doucet, manager of the Emulsifier Innovation Center at Caravan Ingredients, Lenexa, Kan., says that in some applications, manufacturers looking for fats and oils containing no trans-fat have been able to switch from using hydrogenated fats to fully refined oils such as soybean oil, sunflower oil, corn oil, etc. “For other applications requiring structuring properties, palm fats and fractions have been substituted. Given the higher saturated fat content of such options, another approach would be to include a fully refined oil structured with Trancendim, which is our line of high diglyceride products that helps manufacturers achieve a 0 g. trans-fat product, as well as reducing saturated fats,” Doucet explains. Trancendim products from Caravan Ingredients can be used to produce par-fried potato products, peanut butter, donuts, bars and various chilled and frozen dough products. “With health and wellness trends sweeping the nation, consumers are becoming more informed about the ingredients in the food they eat and are increasingly
aware about trans-fat and saturated fat,” he says. “The greatest challenge or opportunity is managing cost for the balance of function versus nutrition.” Doucet says that the company is currently working on combining Trancendim with products such as Olean to enable the production of shortenings that perform better than other hardstock. Caravan Ingredients can create formulations using Trancendim to structure a variety of fats and oils, including Olean to meet certain baking needs, he says. “Caravan Ingredients works with manufacturers to structure the more unsaturated oils to give the functionality of a structured, saturated fat [that] is required. Although palm has a negative connotation for having high saturated fat levels, it provides for many applications the necessary processing and quality requirements.” Not fully understanding the role of fat from a processing and quality perspective is often a common mistake processors encounter. “In many cases, it just isn’t possible to verify the functionalities [of fats and oils] until commercial trials are run and shelf-life evaluations are performed,” Doucet says. “Caravan Ingredients’ innovation center and product development center can provide starting formulations for most bakery and snack products, and our technical staff can help with formulation specific issues.”
Foods with functionality Arista Industries, Wilton, Conn., offers natural vegetable oils, organic oils and powder-form oils for snack foods and bakery products. Healthier oils without trans-fat are used as ingredients and for frying/baking. The powder-form oils are being used in dry formulas and bakery applications for added functionality. “Many snack foods used to be viewed as junk food, but with many chips now baked, not fried and made with healthier oils, like canola, safflower, sunflower and olive oil as well as organic oils, there are now many healthier alternatives to the traContinued on page 60
58
Snack Food & Wholesale Bakery - August 2011
www.snackandbakery.com
Whe n y o u r labe l s ay s “0 g t r an s -f a t” w o u l d n’t you l i k e t o rea l ly me a n i t ?
Ingredient Technology Continued from page 58
ditional products,” says Maryann Siciliano, national sales manager. “Consumer trends lean toward healthier products as well as foods with functionality, like the addition of Omega fatty acids to bread and snack foods make with organic oils. The current trend is to use healthier oils containing monounsaturated fat, antioxidants, carotenoids, tocopherols, tocotrienols, vitamin E and micronutrients.” Siciliano says the most popular fats and oils are canola, safflower, sunflower and olive oil. “They do not contain trans-fat and Photo courtesy of Arista Industires
are fairly stable in frying and baking applications. Many of these oils have cardiovascular benefits and help lower cholesterol and risk of heart disease,” she adds. Arista’s research and development department works with bakers and snack producers, suggesting the best ingredients regarding functionality, smoke point and shelf life based on the specific product being produced. “We can help bakers and snack manufacturers develop new products and stay abreast of trends by providing technical information on our ingredients and relaying what we hear going on in these markets,” Siciliano adds. “Most of Arista’s oils are fully refined for maximum shelf life,” she says. “We provide full documentation regarding nutritional information, allergens, genetically modified organisms (GMO) status and Bovine Spongiform Encephalopathy (a.k.a., Mad Cow Disease-BSE).” Siciliano says the biggest request Arista
60
Snack Food & Wholesale Bakery - August 2011
receives deals with healthier fats and oils. “Consumers do not want to give up snack foods, but feel better about consuming better products that may also have some added functionality,” she says.
High-oleic canola oil The IFT show generated several new developments in fats and oils. Cargill, which launched Clear Valley 80 high-oleic canola oil at IFT, says the new high-oleic oil is the next generation to deliver the best flavor, stability, consumer label and packaging cost reduction available in any vegetable oil. The natural, high-oleic oil has the same nutritional benefits featured in earlier generations of Clear Valley products but is a first-of-its-kind product because of its low levels of saturated fat, 0 g. trans fat (per 14-g. serving) and an exceptional, costsaving shelf life. With low levels of saturated fat and 0 g. trans fat (per 14-g. serving), Clear Valley 80 high-oleic canola oil provides the most consumer-friendly label of any vegetable oil currently available. Clear Valley 80 resists oxidation and the development of flavor off-notes, which allows food manufacturers to forego familiar formulation challenges associated with the use of canola oil to create great-tasting snacks and baked products, says Willie Loh, vice president of marketing at Cargill Oils & Shortenings, Minneapolis. “For more than 15 years, Cargill has been developing high-oleic canola oils with increased heat and oxidative stability,” Loh states. “Unlike oils that can develop ‘grassy’ and ‘painty’ off-notes when oxidized, high-oleic oils have natural resistance to oxidation without going through hydrogenation, fractionation or other complex processing.” Cargill also offers a shortening designed to help bakers make Omega-3 nutrient content claims: Clear Valley Omega-3 shortening helps bakeries grow their top lines by capitalizing on consumer demand for adding Omega-3 sources to their diets. The shortening can differentiate bakery products with the addition of a Food and Drug Administration Modernization Act
Photo courtesy of Cargill Oils & Shortenings
nutrient content claim for ALA Omega-3. Clear Valley oils and shortenings work in shelf-stable applications such as cereal bars, baked snacks and baked goods, says Kyle Marinkovich, marketing director, at Cargill Oils & Shortenings. “Today’s focus is not only in eliminating trans-fats; we are also focused on decreasing saturated fats, offering a total system cost reduction and providing a nutritional balance,” Marinkovich says. Because consumers will gladly give up fat in the diets yet won’t give in on flavor, Cargill developed CitriTex GSG71 as a fatreplacement system that can replace oils in bakery sweet goods. CitriTex blends reduce fat without compromising taste or texture and often without increasing costs. They allow bakers to replace up to 50% of the oil to create a great-tasting muffin that contains 44% less fat versus a full-fat muffin. “The new corn muffin formula used MaizeWise whole-grain corn flour products that deliver 100% whole-grain nutrition,” Marinkovich adds. Also included in the formulation was Clear Valley Omega-3 oil, and low-cost canola-flax oil blend, which provides food manufacturers with a method to add alpha-linolenic acid (ALA) Omega-3 to shelf-stable products without affecting product taste, mouthfeel or shelf life. This new generation of high stability oils offers superior stability. Clear Valley 80 has the highest levels of oleic acid and the highest level of oxidative stability among all high-oleic vegetable oils for an extended shelf life, reducing system costs,” he sums up.
www.snackandbakery.com
Extending shelf life, safe handling John Nedderson, application specialist, fats and oils at Danisco USA, New Century Kan., says solid fats are typically purchased from a shortening or margarine producer in cubes and are added directly to a product. “Liquid oils are usually purchased from an oil refiner in bulk form, stored in a tank and metered directly into the product. Some bakeries produce their own shortenings. We have applications experience in all types of baked products and snacks.” Danisco offers a full line of ingredients that are used to extend shelf life. These include emulsifiers, antioxidants, enzymes and hydrocolloids. Most of its ingredients contain no allergens. Today, the new fats and oils, in general, are healthier, lower in trans-fat and saturated fats and are higher in liquid oils, says Nedderson. “We see unique uses of emulsified oils in pie crusts, cookies, cakes and crackers,” he says. “Consumers want healthier products and reduced trans-fat and saturated fat, and we see more use of liquid oils and reduced calories. Consumers also desire oils perceived as ‘healthy,’ such as olive oil, Omega-3 oils and plant sterols.” The company is always looking at new trends going forward, developing novel uses of emulsifiers and crystallizing agents to lower saturated and trans-fats, Nedderson explains. Danisco recently launched PinVita phytosterols that can be used in bakery and
Photo courtesy of Danisco USA
www.snackandbakery.com
snack products to help lower cholesterol. “We are working on the development of natural chelators that can be used to replace synthetic preservatives,” he adds. All too often, however, problems can arise with processing fats and oils, and involve improper processing, storage, handling and saving packaged shortenings that are too hot, which can lead to oiling out or holding liquid oils too hot, potentially leading to oxidation. “Another mistake is not selecting the correct fat for the application or not including a crystallization promoter or antioxidants,” Nedderson acknowledges. “We can assist customers with proper ingredient selection and process knowledge to overcome these common mistakes.” But the bottom line seems to be healthy products, so the company is formulating more of them, which is also what customers are doing. “We also have requests for more natural products and cleaner labels,” he says.
“New advancements, such as the development of high-oleic oils, provide the same neutral taste with a healthier, more stable oil profile that is suitable for snacks and baked goods.” Pioneer Hi-Bred is working with oil processers to explore many ways in which Plenish can be combined with traditional oil processes to develop new formulations. “Plenish has the ability to extend shelf life significantly over alternative oils based on the increased oxidative stability of the oil,” Rinehart adds.
Enhanced oils
Lowering the saturated fat
New Plenish high-oleic soybean oil from Pioneer Hi-Bred International, Johnston, Iowa, maintains a reduced amount of unstable fatty acids that provide stability against oxidation without the need for hydrogenation. Fats and oils provide the stability needed for the process, as well as increased shelf life for packaged snacks. According to Amanda Rinehart, marketing communications manager at Pioneer Hi-Bred, the first generations of enhanced oils were introduced as an immediate solution, but in many cases, they didn’t have the stability required for the application. “Plenish high-oleic soybean oil provides the same degree of stability as that of a partially hydrogenated oil for the baking and snack food industry, without the harmful trans-fat. And based on the soy platform, the trait can be delivered in the volumes required by the industry in a costefficient manner,” says Rinehart. Plenish was created using biotechnology to modify the fatty acid profile of soybean oil, Rinehart says. “Flavor also is an important component of a food company’s oil selection,” she adds.
SunOpta Grains and Foods Group, Hope, Minn., focuses on specialty fats and oils, such as expeller-pressed, organic and/or non-GMO products. Its research and development team works with customers to select the best ingredients for their applications. The company can also customize an ingredient for specific needs and develop products to exact specifications. Its newest product line is organic palm products, which are ideal for replacing hydrogenated oils. With expeller pressing, a screw-type machine presses the oilseed to mechanically extract the oil. The pressing process separates the oil from the fiber solids without any chemical solvents. Expeller pressing does not use any harsh chemicals in the process and produces a higher quality oil. “Canola and soybean oil are the most popular,” attests Caren Montante, specialty oils manager. “Canola oil is the lowest saturated fat oil, and soybean oil is plentiful and the most economical.” Montante points out a common mistake many processors overlook: The least expensive oil or fats aren’t always the best choice for a specific application. “We work
Photo courtesy of Pioneer Hi-Bred International
Continued on page 62
August 2011 - Snack Food & Wholesale Bakery
61
Ingredient Technology Continued from page 61 Photo courtesy of ADM Oils
with customers to create ingredients that fit the specific application, whether it’s a new flavor or new type of ingredient,” she says. We continue to work with growers to institute new programs for advanced oilseed breeding, for example, high-oleic soybean oil and high-oleic canola oil. High-oleic hybrids will extend shelf life on the finished products.” One challenge SunOpta finds is that every year, the supply on certain oils can be dicey. “On the cost side, risk management is always a challenge,” Montante, says. “We are working to develop other strains of oilseeds for better results in specialty oil applications.”
More whole grain and fiber Today’s bakers and snack producers are looking to develop snack and bakery products that contain 0 g. trans-fat per serving, along with low to moderate levels of saturated fats, says ADM’s Tom Tiffany, senior technical manager. “ADM Oils works with a variety of applications that help support the snack and bakery industry,” Tiffany notes. The technical team works with a variety of bakery applications, including icings, snack cakes, pastry, donuts, cookies, etc. “More snack and bakery products are being formulated to include whole grain and fiber,” he says. “Oils and fats used in these new types of products help improve
the texture, flavor and moistness. They also deliver flavor, structure and nutrition to the new snack foods. Food companies are looking for oils, fats or blends that provide them with functionality, shelf life, good flavor, proper nutrition characteristics and cost management. Palm blends and interesterified soybean oil are popular shortenings for bakery applications. Mid-oleic sunflower oil, cottonseed oil and higholeic/low-linolenic canola oil are popular oils for snack food applications.” The Decatur, Ill.-based firm works closely with customers on product development to help them identify an oil or shortening that will meet their functional, nutritional and economic needs, Tiffany adds. Currently, ADM Oils is working more with enzymatically interesterified soybean oil, a product it introduced in 2003. “This product continues to receive attention as food companies look for soybean oil-based shortenings,” Tiffany says. “Interesterified soybean oil-based shortening can act as a drop-in replacement for partially hydrogenated vegetable oils. In some instances, processors and bakers can underestimate the complexity and the functionality that oils and fats contribute to the finished food product. Nutritional, economic and functional demands will continue to create challenges for the edible oil industry,” he says. “High-oleic soybean oil could help meet challenges for shelf life, functionality and nutrition. This oil can be used alone, in blends with solid fats or as the liquid component in enzymatic interesterification.”
Some things don’t change With respect to the world of fats and oils, the more things change, the more they remain the same, according to Roger Daniels, director of R&D at Bunge North America, Bradley, Ill. “Shortening, margarine and oils as ingredients are subsets of snack and bakery products,” Daniels says. “The overarching trends we see are taste, quality, convenience and price as tier one, followed by health and wellness, simplification, sustainability and safety as tier two. In snack frying, there is strong demand for high-oleic oils balanced with traditional
oils derived from soybean and canola. In bakery applications, there is strong demand for domestically sourced soybean oil-based ingredients subjected to our proprietary partial hydrogenation process, or Ultrablends Enzymatic Interesterification process and palm oil-based. Bunge Oils’ Ultrablends Enzymatic Interesterification products and our high-oleic canola oil offering provide two approaches to achieve this trend,” he says. The company’s latest products include saturates sparing shortenings. “The allpurpose and emulsified shortening variants deliver improved nutrition with broader applications potential from functional bakery shortenings,” he explains. “Key highlights include 0 g. of trans-fat per serving, lower saturated fat levels (greater than 33%) versus traditional functional shortenings and higher heart-healthy monounsaturates and polyunsaturates levels over traditional functional shortenings.” Bunge Oils’ customers are asking for shortening, margarine or oil ingredients that contribute to snack and bakery products that work each and every time in four basic areas: the shop (plasticity allows the dough to machine well), on the shelf (stability of the shortening, margarine or oil in terms of the ratio of liquid oil to solids balanced to prevent oiling out during the distribution and a balanced approach of polyunsaturates and saturates to maximize flavor performance in terms of shelf life), on the plate (the product delivers taste, quality, convenience and price) and in the consumer (the product has taste, quality, convenience and price, augmented with healthful oil options). SF&WB
Photo courtesy of SunOpta Grains and Foods Group
62
Snack Food & Wholesale Bakery - August 2011
www.snackandbakery.com
Ingredient Briefs
J.R. Short introduces a low-expansion tortilla pellet that can be produced as a micro pellet for pressure puffing. The unique crinkle shape, formulated with 100% whole grain, delivers the texture consumers expect from traditional, higher fat content tortilla chips. The pellets also come in a medium-range expansion that can be air popped, lowering the fat. J.R. Short Kankakee, Ill. 800-544-8734 www.shortmill.com
Kemin introduces GT-FORT, a natural flavor that can be used as an alternative to synthetic antioxidants and tocopherols commonly used in frying oils. GT-FORT is a green tea-based, water-soluble liquid extract that is oil dispersible and effectively slows the deterioration of frying oil, reducing oxidative rancidity even at high temperatures. The unique multi-stage extraction process used to manufacture GT-FORT maximizes the polyphenols, which provide effective antioxidant properties, and delay oxidation in a variety of fried food applications. Kemin Food Technologies, division of Kemin Industries Des Moines, Iowa 866-253-9579 www.kemin.com
SF&WBtv www.snackandbakery.com
Thymly introduces #1 Perfection, a dough conditioner created to replace harsh chemicals for a cleaner-label product. The all-natural enzyme conditioner is a balanced combination of wholesome, freeflowing ingredients with a high degree of uniformity. #1 Perfection eliminates bitter off-notes for improved taste, says the company, and strengthens dough for dependable and resilient performance. It also reduces the need to adjust formulas and is a cost-effective way to diminish chemicals. Thymly Products Inc. Colora, Md. 877-710-2340 www.thymlyproducts.com
Walnuts add great taste, mouthfeel and nutrition to any product. In fact, 76% of consumers indicate they will purchase a food product because the label says it contains walnuts, according to the California Walnut Commission. Just 1 oz. is an excellent source of ALA, the plant-based Omega-3 fatty acid. Walnuts also provide 4 g. of protein, 2 g. of fiber and many antioxidants. Walnuts can add value to many bakery items. California Walnut Commission Folsom, Calif. 916-932-7070 www.walnuts.org
Cargill launches FlakeSelect, a product line that helps food manufacturers reduce sodium in baked goods, snacks and processed foods or reformulate with sea salt while maintaining a salt taste. The line comes in FlakeSelect Kcl (potassium chloride), FlakeSelect Kcl/Salt, FlakeSelect KCl/Sea Salt and FlakeSelect Sea Salt. FlakeSelect shows better adherence for topical applications and can be customized based on a customer’s needs. Cargill, Inc. Minneapolis, Minn. 952-742-6360 www.cargill.com
Comax Flavors offers an authentic line of flavors inspired by traditional Hispanic cuisine. Covering everything from sweet to spicy, the host of flavors includes mango, papaya, passion fruit, lime, guanabana (a mixture of strawberry and pineapple with an underlying creaminess of coconut or banana), Acerola (also known as the Barbados cherry) and Lulo (a blend of rhubarb and lime to offer a citrus twist). On the spicier side, Comax supplies chipotle pepper, jalapeño, Mexican spice, taco spice, sangria, avocado, Mexican vanilla, Sofrito (a sauté of onion, garlic, oregano, cumin, bell peppers and tomatoes), Chamoy (a combination of salt, sweetness and heat infused in apricot) and Cajeta (a Mexican confection of thickened syrup made of sweetened caramelized milk). Comax Flavors Melville, N.Y. 631-249-9255 www.comaxflavors.com
View videos demonstrating the newest bakery & snack food ingredients by visiting
www.snackandbakery.com
August 2011 - Snack Food & Wholesale Bakery
63
PACK EXPO Pre-show Coverage
The Power of Packaging T
he power of packaging is contagious. That’s why the Packaging Machinery Manufacturers Institute (PMMI), the Reston, Va.-based organizer of Pack Expo Las Vegas 2011, is, as always, presenting one powerful show. Pack Expo Las Vegas 2011, scheduled to take place Sept. 26-28 at the Las Vegas Convention Center in Las Vegas, promises to give visitors an opportunity to connect with 1,600 world-class suppliers, find total systems solutions and cutting-edge technologies and attend industry pavilions
64
Snack Food & Wholesale Bakery - August 2011
and an enhanced conference program led by industry leaders. The show will kick off with keynote speaker, General Colin Powell, former U.S. Secretary of State. In his address titled “Diplomacy: Persuasion, Trust & Values,” Powell will discuss how he defied racial barriers and how his leadership skills helped him become chairman of America’s Promise Alliance, an organization that works with more than 400 partner organizations to provide resources that build better lives for America’s youth.
Attendees can connect with the snack food and bakery community via the baking and snack break lounge, a meeting place established to offers specialized opportunities for baking and snack professionals to connect with suppliers and partners for even faster access to the solutions they seek. The lounge will house an “Ask the Expert” resource center staffed by the Snack Food Association, Arlington, Va., (also the endorser of the lounge), where attendees can receive guidance from experts on specific packaging- and processing-related challenges. In addition, a micro-site is being created, which will feature baking and snack trends, news, live blogging from experts on the show floor and other showrelated tidbits. Industry executives can also attend a reception on Sept. 26 and receive an additional opportunity to network with industry peers. In addition to the industry-specific lounge, Pack Expo Las Vegas remains home to the Processing Zone, where attendees can find innovative processing solutions for the food, baking and snack industries. Meanwhile, the Confectionery Pavilion is a venue where snack producers can find innovations that address specific packaging and processing challenges, enhance versatility, minimize changeover time, maximize convenience, guarantee freshness
www.snackandbakery.com
Exhibit Show Hours Monday, Sept. 26 Tuesday, Sept. 27 Wednesday, Sept. 28
9 a.m. – 4 p.m. 9 a.m. – 4 p.m. 9 a.m. – 4 p.m.
*Exhibit show hours are subject to change.
and more. The Confectionery Pavilion is sponsored by the National Confectioners Association, Washington, D.C. The Reusable Packaging Pavilion, sponsored by the Reusable Packaging Association, Arlington, Va., showcases how choosing reusable pallets, hand-held containers, bulk containers, dunnage and
www.snackandbakery.com
other transport packaging solutions can raise productivity and profitability. Attendees can swing by the Food Safety Summit Resource Center and learn from subject matter experts on the latest breakthroughs in food safety and receive insight into potential solutions. Lastly, the Brand Zone—Containers
& Materials that Shape Winning Brands, offers the latest advances in package design for glass, plastic, metal and paperboard packaging, decorating and labeling techniques. And the Showcase of Packaging Innovations features award-winning packaging from around the world. The 6th annual Pack Expo Selects awards recognize best-in-class consumer packaging by exhibitors. And, Project 2020: The Consumer Experience focuses on the future of packaging with a design competition that forecasts upcoming trends. For exhibitor and attendee information, travel arrangements, airfare discounts, registration links and more, go to www. packexpo.com. SF&WB
August 2011 - Snack Food & Wholesale Bakery
65
PACK EXPO Booth Profiles
Editor’s Note: Booth numbers are current as of July 25, 2011
MOEN Industries Booth # C-1630
Need to boost packaging efficiency? Turn to Heat and Control for the latest machinery and pre- and postsale support services for weighing, tray sealing, metal detection, x-ray inspection, checkweighing, conveying, snack bagmaking, seasoning application, seal checking, food processing, controls and MES. Heat and Control, Inc. Hayward, Calif. 800-227-5980 www.heatandcontrol.com
MOEN Industries is a leader in the design and manufacture of quality corrugated Bliss Box formers, tray formers and top sealers, specializing in Bliss Box designs and assorted tray styles. Designed for longevity, this ruggedly built line of equipment is field-proven to be reliable in high-volume, multi-shift operations. Bliss Box designs are ideal for an array of products requiring high-strength packaging. Whether the need is for a shipping container or a displayable package, versatile Bliss Box designs provide the flexibility to meet the demands of the marketplace. In addition to providing more stacking strength compared to a regular slotted container, Bliss Box designs allow a mix of material board combinations for efficiency and in some cases, reduced material usage compared to a regular slotted container (RSC). MOEN Industries Santa Fe Springs, Calif. 800-423-4747 www.moenindustries.com
Kwik Lok Corp. Booth # 1833
Reiser Booth # 5335
Kwik Lok Corp. was founded in 1954 by Floyd Paxton when he invented that “funny little plastic clip.” Known as a Kwik Lok, the clip was developed to provide a fast, simple solution to quickly closing apple bags on handbagging lines. Today, the plastic clip offers even more. Kwik Lok has addressed traceability and recall concerns by offering a wide range of printing options, including cold foil, laser, ink and thermal transfer solutions. Each option presents a wide range of printing capabilities to include real-time display, 2D bar codes, best-before dating and plant code information, all available in one consistent easy-to-read location. Kwik Lok Corp. Yakima, Wash. 800-688-5945 www.kwiklok.com
Reiser will feature live demonstrations of its complete line of processing and packaging equipment and solutions. Of special interest to food packagers will be Reiser’s wide variety of packaging solutions, including Repak horizontal form/fill/sealers, Ross tray sealers and Supervac vacuum chamber packaging. Live demonstrations will highlight Reiser’s automatic processing-to-packaging solutions. Reiser will demonstrate its Vemag hamburger patty forming system in combination with the Repak. The Vemag system forms exact-weight gourmet hamburger patties, which are then conveyed from the Vemag, placed on to carrier paper, automatically indexed and loaded into the Repak where they are packaged. This solution is ideal for high-volume applications. Reiser Canton, Mass. 781-821-1290 www.reiser.com
Heat and Control, Inc. Booth # C-2433
66
Snack Food & Wholesale Bakery - August 2011
ADVERTORIAL
www.snackandbakery.com
Editor’s Note: Booth numbers are current as of July 25, 2011
PACK EXPO Booth Profiles
BluePrint Automation Booth # C-2439 BluePrint Automation (BPA) will showcase its rainbow feeder with “on-the-fly” Delta vision robotic system, designed to transfer product from bulk to a visionguided robotic cell. With BPA’s two-pick solution, the robot is able to pick, rotate and then pick again before rotating both to the orientation required and placing in the dinner tray, clamshell or hff/f/s. This system delivers high-speed accuracy as it picks multiple items, one at a time, at random orientations and then places them both into two different trays, simultaneously. The rainbow feeder unscrambles and feeds rigid and flexible packages from bulk storage at 215-plus parts per minute (PPM). Product is then conveyed out of bulk storage and transferred to the rainbow feeder, which is composed of 26 individual servo-driven singulation stations. BluePrint Automation, Inc. Colonial Heights, Va. 804-520-5400 www.blueprintautomation.com
Wire Belt Co. of America Booth # 1155 Wire Belt, the leading developer of open-mesh, stainless-steel conveyor belts, has been keeping lines running for more than 60 years. Its conveyor belts are extensively used for breading, battering, frying, blanching, cooking, coating, dusting and cooling. Wire Belt’s latest innovation, the CompactGrid conveyor belt, is specifically engineered to replace heavier balanced weave belts and difficult-to-clean plastic modular belts. Engineered with 70% open surface area, CompactGrid conveyor belts provide optimal performance in processes where product coating, drainage and liquid or air circulation are factors. Its entire line of belting products is accepted by the USDA NSF/ ANSI/3-A hygiene standards. Wire Belt Co. of America Londonderry, N.H. 603-644-2500 www.wirebelt.com
ADVERTORIAL
Production Technology Dividers & Rounders
Divide, Round and Conquer Dividers and rounders are vital to producing perfectly shaped breads, ro lls and more. Here are some of the most recent advances in technology that facil itate smooth production. Lauren R. Hartman, Editor-in-Chief
reating a signature loaf of bread isn’t all that easy; techniques must be practiced in order to generate eye appeal from a single batch of dough and add value, while automation must help save on labor and time. Equipment that effectively imitates a hand-tossed look is crucial in some cases, such as for pizza dough. But with so many innovative bread product introductions, varieties and goals to create that hand-crafted look and feel, equipment manufacturers must customize their systems to provide solutions for individual production needs. Often, different bakery products are made on the same equipment, so it’s important that production lines be flexible to handle the changeovers. And though economics may never be back to “normal,” many companies are eager to start reinvesting in equipment that provides good value. Dividers can be the “cash registers” of the line, so having tight control on these systems can pay for equipment very quickly. Weight issues associated with dividers tend to magnify downstream issues. So how does Reiser meet the needs of customers who look at the trends? John McIsaac, vice president of strategic business development for the Canton, Mass., company, says that many customers are looking for that versatility with their dividers and rounders. “We have always responded,” he says. “The Vemag dough divider is easily adjustable to produce a range of
C
exact-weight portions, dough absorptions and crumb structures. In these uncertain times for commodities, customers are looking for opportunities to save on ingredients by improving weight control. Of course, they would like to couple this with improved product quality,” he says. “We need to stay vigilant to make sure we maintain our position of providing the best of both.”
One size doesn’t fit all McIsaac says his firm is also looking for customers that prefer to run a dedicated product on a particular divider, and wants the machine optimized for that product. “To that end, we have expanded our machine range to match capacity to the application more precisely. We know one size does not always fit all. Our product specialists and engineers listen to our customers to make sure the machinery and support we provide matches their needs.” The top-selling Vemag HP-E Series
dough divider and the smaller Vemag 500 series are both growing in popularity for use in larger bakery applications. The Vemag can be used to produce breads, rolls and buns and is easily adaptable to all ranges of dough absorptions and crumb structures. The HP-E is a single-line machine featuring the latest servo technology and a double-screw pumping system that provides gentle handling and the highest levels of portioning accuracy with virtually no giveaway. The double-screw’s positive displacement prevents overworking the product and transports the product from a hopper to the machine outlet without damage. The system handles large inclusions and heavy doughs with ease. The double-screw is available in a variety of configurations and portions from 5 g. to 20 kg., at speeds up to 1,200 portions per minute, depending on the application. “There is significant growth in overseas markets, but we see much opportunity in North America for equipment that can do a better job than present traditional technology,” McIsaac says. When it comes to purchasing dividing and rounding equipment, important factors include return on investment (ROI), product quality, versatility and support, he points out. And there are challenges with dough. “The product—the dough ball—is live and ever-changing,” he adds. “That means characteristics such as density are also changing. Operating 24 hours, six to seven days-per-week, leaves little time for maintenance. Many bakeries are so busy, that it’s difficult to show operators how to simply and efficiently operate equipment. We thrive despite the challenges, and the challenges make us better.” Reiser installed Vemag systems in Continued on page 70
68
Snack Food & Wholesale Bakery - August 2011
www.snackandbakery.com
The Vemag Dough Divider produces uniformly spaced dough portions onto the conveyor, eliminating doubles and downtime. It can be easily converted to a two-lane set-up to produce up to 200 cuts per minute.
W H Y
T H E
V E M A G
is a B E T T E R D O U G H
D I V I D E R What makes the Vemag Dough Divider so special? Versatility and weight accuracy. The Vemag Divider adds versatility to every production line and is perfect for all types of breads, buns, rolls and English muffins. It features a positive displacement double screw system that is the most gentle extrusion divider on the market. The Vemag is easily adjustable to produce a range of exact-weight portions, dough absorptions and crumb structures. See for yourself – call us today for a free DVD or to set up a demonstration.
The Vemag is easily adjusted to produce both open-crumb and uniform tight-crumb structures.
The Vemag does not require mineral oil, saving thousands of dollars annually while eliminating product air pockets and surface blisters.
Batch after batch, the Vemag consistently produces precise weight portions at 1% standard deviation.
The Vemag is easily adjustable to produce a wide range of portion sizes – from 5g to 20kg.
Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com
The Vemag can handle absorption rates from 45% to 95% – from stiff bagel doughs to soft English muffins.
Leading the food industry in processing and packaging solutions.
Production Technology Continued from page 68
many segments of the bakery industry, from high-speed muffin and roll lines to fresh and frozen pizza dough, cookies and fillings lines. The same machine that runs English muffins can quickly be changed to run hamburger buns. With a simple changeover of attachments, the Vemag can also be used as a cookie dough depositor, a filler or a sheeter. “Does this constitute a hybrid machine? Probably. Our goal is to provide a machine that solves customers’ problems, be it weight control, product quality, increased capacity. If one of those issues is versatility, we have expertise in providing a machine that can run multiple products,” he says. While performance is the driver, customers continuously ask for more sanitation features. “Sanitation is gaining,” says McIsaac. “Product changeover is plantspecific, so some systems do a lot while some run similar products all day long. All of our customers want the capability to positively pump the product through the divider and minimize downtime for changeover. The idea that the oven solves all food safety issues has passed.” He also says that customers want machines that are easy to clean. “They are also looking for stainless-steel and Food and Drug Administration (FDA)-approved product-contact materials. They want to be able to easily inspect all product contact surfaces without breaking out the tool box.”
Photo courtesy of WP Kemper Bakery Systems
running could be designed in the future,” McIsaac says. He also sees a direct tie-in of these systems to all of the process control and management systems on a line, regardless of the provider. “We also see future machines that can tell the producer and us when they need maintenance. Machines with even tighter weight tolerances held and simpler operation and care could be created.” Dividers aren’t what you’d call inexpensive, he admits, so customers want to get the best value for their money. “They want to know ROI, most often using improvement in weight control and capacity as a basis,” he says. “They also want support and equipment suppliers that are going to be there for the long haul. We try to sell a machine that pays for itself in productivity and weight control.”
Segments thirsty for innovation Some of the new equipment being designed by Reiser includes systems for segments of the bakery industry that haven’t seen innovation in some time. “We are customer-focused, and customers are suggesting products for us to develop [that would work with] our divider/rounder systems. We respond to the market, and the market has shown a need for the versatility, sanitation and weight control that we can consistently deliver.” McIsaac sees dividers and rounders of the future being more integrated into production lines. “Systems that tell how much they produced, when they’re running, how fast they’re running and why they aren’t
70
Snack Food & Wholesale Bakery - August 2011
Bigger is better When it comes to these systems, bigger is better. However, several companies polled admitted that there weren’t too many new developments in dividers and rounders because of they’re proven technology, says Jim Souza, vice president and director of industrial sales at WP Kemper Bakery Systems of the WP Bakery Group, Shelton, Conn. “Our customers want increased capacity, more hygiene and sanitation features, faster throughput speeds and stainless-steel, easy washdown equipment,” he says. “We see the trends in this area being bigger, higher-capacity equipment. Custom-
ers want larger batch capacities, nearing 1,000 pounds per hour, and our equipment is designed just for those needs.” Patricia Kennedy, president of WP Kemper, says customers want something flavorful. They’re also asking for better, wetter doughs with higher fermentations at higher speeds, and want higher performance and easier changeovers. “They’re looking for a quality, upscale, healthier product with value. This is driving bakeries to add more water and preferment with some bulk fermentation time to their products. Our technology is a perfect fit for this need. The SoftStar+ allows for higher hydration, yet high speeds and flexibility can be maintained.” Launched in 2010 to the North American market, the SoftStar+ line is proving itself with several customer installations. It has 68-69% hydration with up to an hour and a half of bulk fermentation time while maintaining speeds of 30,000 pieces per hour. “Customers are ecstatic at the incredible savings of water—up to 3% of the formula,” Kennedy says. The top-selling SoftStar and the SoftStar+ are high performance dough and moulding machines for industrial use. They include a resting zone between the measuring drum and the moulding belt with hydraulic dividing system, along with a multi-measuring drum that has two weight measures. “This allows us to use higher hydration doughs with lower fermenting times,” she says. “The SoftStar+ also has a large door for easy access. All sanitation points are easy to get to and easy to clean. For changeovers, the multi-measuring drum allows for weight changes, so drums don’t have to be changed.” Labor is always a big concern, along with the overall cost of a machine. she adds. Because the SoftStar+ allows bakers to add more water to formulas, this creates
www.snackandbakery.com
Production Technology an attractive ROI, she says. “Customers are thrilled when they hear they can add more water and increase their ROI with SoftStar+.” Kennedy adds that important factors to consider when purchasing dividers and rounders are that customers are able to increase hydration of current formulas. “This allows dough to rest longer to increase flavor. It also brings tremendous savings to customers. Increasing hydration is a great way to increase the opportunity for growth in this market, along with bringing flavor with bulk fermentation and maintaining a high output. The SoftStar+ allows for an increase in dough hydration.” SoftStar+ is a hybrid machine, she says. “It can handle straight dough but it can also handle bulk dough with a higher fermentation.” One challenge WP Kemper Bakery Systems sees for customers is that their markets change. “It’s impossible to know if they will need to make stamped rolls or long moulded rolls or need a longer intermediate proof time in the future from what we know today,” Kennedy says. “This is the advantage of our lines. WP Kemper Bakery Systems can overcome those challenges because our lines can evolve. We can add stamping stations with no real downtime. We can add more intermediate proofing time with less than one day of downtime. Our modules are plug and play, making every line flexible.” Look for a lot of new designs from the company to debut at iba 2012, Nov. 1621, 2012 in Munich, Germany, she says.
Don’t forget flexibility Bruce Campbell, vice president, dough processing technologies at AMF Bakery Systems, Richmond, Va., says the most important emerging trend in dividing and rounding equipment is flexibility, flexibility, flexibility. “The consumer demands a wider variety of products and therefore bakers are looking for efficient equipment that can offer this flexibility,” Campbell says. “Bakers want equipment that can make a wide
variety of known products and offer the flexibility to take on future products yet to be developed. For instance, soft-roll lines are being looked at to make a wider variety of products. Rolls like the chicken roll, sandwich thins, etc., are now being made on AMF divider/rounders that used to be exclusively for soft buns. This has driven customers to ask for dividing technologies
Photo courtesy of AMF Bakery Systems
that can handle a wider variety of doughs, from stiff to slack.” Campbell points out that product quality continues to be the No. 1 issue for bakers. “Efficiency, accuracy and sanitation are all the focus of new make-up equipment design at AMF,” he says. “While there are some new products adding to the bottom line, increases in commodity and energy costs have resulted in a close analysis of costs in every aspect of production and maintenance.” An example of this is in the flour tortilla market, he says. “Just like new processing methods changed the bread and bun industry in the late 80’s and early 90’s, there are new processing methods for flour tortillas that allow producers to enjoy higher accuracy, lower capital investments and much lower maintenance costs. The trend to more varieties of tortillas has made more of a case for new, continuous processing technology because they easily change from one variety to another with the touch of a recipe management button.” Campbell says there continues to be a shift from volumetric dividing to extru-
sion, especially with bread items. “While the market was growing like crazy 20 years ago, producers didn’t worry about accuracy or maintenance budgets as much; they only worried about growth. Now, that they need to fight for bottom line profit growth, they’re looking at the efficiency, accuracy and maintenance issues of the existing technology [they have, which] is making them consider new technology to help the bottom line and increase productivity.” AMF’s new Do-Flex divider offers a new technology that replaces the traditional pump/valve combination that AMF has used for more than 25 years on its SBD and HBD bun dividers. “While the standard technology is still available on the HBD and works very efficiently on regular bun production, the Do Flex allows for drastically lower dividing pressures (less than 20 pound per square inch [psi] versus manifold pressures close to 100 psi on previous high-speed lines)” states Campbell. “This low-pressure dividing process makes the Do Flex system flexible for a wide variety of dough conditions. Accuracy is also substantially higher than any other divider available on the market.”
Extrusion technology At rates of 145 cuts per minute on an 8-pocket line, the Do Flex divider and AMF’s belt rounder system control portion accuracy and require no major rebuilds every few years. The Do Flex is available in multiple pocket configurations from four, six, eight and even nine pockets. “Now, the largest and most profitable bakers use new extrusion-style technology,” he says. “Producers need to recognize that it’s inevitable if they want to compete, that they improve the efficiency of their divider and rounder operations. We have successfully converted several bakers that were using ‘hard roll’ technology and trying to supply customers’ demand for soft rolls using that same equipment. Adding an AMF Accupan Bun make-up line and taking a significant portion of the production off the other roll lines, they were able to gain substantial efficiency and flexibility to make a wide variety of products.” Continued on page 72
www.snackandbakery.com
August 2011 - Snack Food & Wholesale Bakery
71
Production Technology Continued from page 71
He admits that the footprint of the new continuous-style dividers and rounders for bread and rolls is slightly larger than a typical volumetric-style machine. “Some are wedged in the corner of a plant, so it’s difficult to find space for new technology. But the rewards are proven by the highvolume bakers in the industry.” Features that customers ask for most from AMF that they didn’t ask for five years ago include the ability to run stiff roll doughs and slack muffin-type doughs on the same line, says Campbell. “They also want PLCs, recipe management and communications like Ethernet, higher performance and more sanitation features,” Campbell says. “An investment is still an investment,” he sums up. “In a tight market, bakers must make serious decisions on where to invest limited resources. Every company has their own unique set of circumstances, therefore, there are bakers ‘making due.’ It’s our position that these bakers need to make sure they clearly understand the benefit of a divider/rounder investment so that they can make an informed decision on how they put their limited resources to work. Volumetric dividers have been proven to cost significantly more to operate in terms of efficiency, accuracy and sanitation and maintenance costs. New AMF extrusion divider/rounders are very simple to clean and maintain and require much less from the maintenance budget to keep in good operating condition.” Some of the pizza manufacturers J.C. Ford works with are looking for a more uniform pizza, which its equipment can deliver, says Kyle Armstrong, sales manager of the La Habra, Calif.-based company. “The main driver for us is the tortilla industry [is] showing the efficiency of this new divider against competitors. We are also targeting the bakery industry as it compares with the best machines used for rolls, etc. Two years ago, J.C. Ford added a JBS rounder/divider to our line, and it has improved the efficiency and output of our tortilla line immeasurably. This divider is more efficient, gives a better product and is more dependable than our previous divider.
72
Snack Food & Wholesale Bakery - August 2011
It compares with the market leaders in rounder/moulders.” When it comes to what customers look for, efficiency, performance, price, accuracy, low downtime and speedy changeovers rank top on the list, Armstrong says. “Customers are interested in the whole package, but always consider the initial price as their primary concern. To produce a rounded dough ball using less moving parts and less energy is the main goal. For us, the greatest opportunities for growth in this market are in the bakery industry, where we offer a machine comparable with the market leader,” Armstong adds. The company has built machines for dough balls as large as 400 g. for pizza production, and its latest divider will process most doughs used to make bread rolls. It’s also designing another machine that rolls dough balls using bands instead of drums, eliminating many moving parts.
high dough hydration capabilities, gentle dough dividing, machine durability, service and parts availability, machine availability and price,” he points out. “Our equipment provides the highest weight accuracy achievable in the industry, typically within 1% of the target weight. This is extremely important, as the requirement for very consistent weights is a top requirement. Another important factor is the capability of a divider/rounder to handle higher hydration doughs that save the customer money on the high cost of flour. Our divider/rounders typically can handle doughs that are 68% hydration and above.” “Another top-selling machine is the mini Rex Futura and this hasn’t changed
More frozen products Koenig Bakery Systems, Richmond, Va., sees more frozen dough/ par-baked roll production lines cropping up or needed to replace existing roll lines for Kaiser rolls, Portuguese rolls, premium hamburger and hot dog rolls, dinner rolls and baguettes. Ethnic-related dough products such as Bilillos and Conchas are also more popular. “Business has grown dramatically,” says Richard Breeswine, general manager. “Koenig machines have remained consistent [in popularity] for the past 40-plus years.” The greatest opportunities for growth lie in large industrial bakeries that update production lines to improve weight accuracy and in medium-sized bakeries looking to cut labor, Breeswine says. Small bakeries and institutional outlets looking for a compact and flexible machine to produce an assortment of rolls and specialty products like bilillos are also growing. “The most important factors when purchasing divider and rounders are weight accuracy, moulding excellence,
Photo courtesy of Koenig Bakery Systems
over the past two years. It has been a top seller for in-store bakeries, casinos, hotels, hospitals, cruise ships and small bakeries,” Breeswine says. The mini Rex Futura produces 1- to 5-oz. dough balls at 4,000 pieces per hour in a two-row operation. “We have been sticking to our core market (high weight accuracy divider/ rounder and flexible roll lines) throughout the economic slump, so that has proven to be a successful strategy,” Breeswine adds. “A purchaser’s primary cost concern is labor and the benefits associated with the labor. Most bakers are looking to cut the high cost of labor through automation and flour costs.” SF&WB
www.snackandbakery.com
Engineering Management
Same Team, Fellas! t’s the bottom of the ninth, with two outs, the score is tied and the home team has a runner on third. Here’s the pitch, it’s a high pop-up to deep short. The shortstop is back-peddling to make the catch, with his waving arms, saying “I got it.” The left fielder is on a dead sprint to the ball as well and “BAM,” the two players collide and fall to the ground, the ball rolling free. The runner scores and the home team wins. We see similar things happen when football players from the same squad dive on a fumbled ball or basketball teammates fight for the rebound and the last second put-back at the buzzer. So many times, from the sidelines, we hear the coach yelling, “same team, fellas.” In today’s competitive industry, we find that the workplace can create its own competition and can provide the arena where some folks feel that they need to be the star. In this scenario, the idea of TEAM is lost. As they say, “there is no ‘I’ in team, but there is a Me.” The ME thing is driving productivity, profits and people right into the loser’s bracket. It still amazes me that you can bring a large number of people together under the same banner, place a mission, vision and company philosophy in front of them, explain that it takes everyone working together to be successful, and then, when you turn them loose on the job, you find out that they can’t play on the same field together without fussing and back-biting. Many managers walk around the workplace talking team, but do they really understand what a team is? They tout that “together, everyone achieves more,” but do they really get it? The motivating posters are on the wall and the slogans are printed on the checks, but the display we see from those managers is usually contrary to the messages they’re trying to send. Why do we see so much dissention across management and the general work-
Jeff Dearduff
[email protected]
I
www.snackandbakery.com
force? Could it be that many people feel that when they take someone else down, there is more personal gain? Maybe it’s the tight economy, the fear of being replaced or maybe it’s just old-fashioned competition? Who knows? Whatever it is, it’s ruining businesses and people’s personal lives, not to mention pushing customers to other providers. How do we get a handle on this problem so that a business can be successful, retain its top-performing employees and its valuable customers? I believe it starts with a true leader who steps up and takes command of the bad situation. Maybe it’s the one who actually recognizes that the ground under their own feet is truly a mess, and they need to do something about it. It might be the person who looks at adversity and sees it as a positive challenge rather than a pain. It takes a very special person and a creative mission to turn a group of people around and operate as a team. Changing the belief structure of an organization requires a strong will, a new set of rules, constant feedback and a regular review of the progress. Just saying “we’re a team” doesn’t do it. Warm and fuzzies always cool off if the belief is not there. Nicey-nice is lost when trust is in question. The person who takes this on establishes the rules, remains transparent, builds trust in others of their own beliefs and
displays a consistent demeanor of calm professionalism. As a result, they will have people follow them into the toughest battle or the biggest game. One of the places that you can see a “team” really work is at the racecar track. In the heat of the battle, you see the crew chief (manager) directing the seven crew members (workforce) who jump over the wall to service the driver (customer). They jack up the car, replace four 75-lb. tires, pour in 22-gallons of fuel, clear the windshield and radiator screen, make an adjustment to the suspension and give the driver a swig of Red Bull, all inside of 16-17 seconds. If just one member of this team fails at their task, the total mission fails and the whole team loses, not just the person who bobbled. If this same crew were to sabotage each other every time the driver comes in for service, the team would never contribute to a win. On the other hand, the driver could actually complete this same service all alone, but it would take much longer and he/she would eventually wear out physically and mentally. Eventually, that allusive win would never come. In the workplace, we are seeing a time where people regularly sabotage each other, which causes all sorts of failures. Too many times, we also see “cowboys” who want to do it all themselves. This is scary, unproductive and dangerous to the business. The magic combination of ideas and beliefs that deliver a solid team may be pretty tough to put in place, but when the correct elements do come together, the team will succeed and win. Team workforces, much like team sports, require cooperation and coordination from all individuals. That’s why I think they invented golf for those who won’t be part of the home team. Rah! SF&WB
August 2011 - Snack Food & Wholesale Bakery
73
Equipment Briefs Heat and Control’s Ishida Atlas-222 bagmaker now comes with durable ceramic anvil knives. Developed for machine tools and parts requiring high resistance to abrasion, high temperatures and corrosion, these knives are made from a proprietary ceramic-metal alloy. They’re also backed by a three-year warranty. Heat and Control, Inc. Hayward, Calif. 800-227-5980 www.heatandcontrol.com Hinds-Bock introduces filling machines for heat-sealing horizontal vacuum formers. Models SP-64 and SP-160 are used over form/ fill/seal equipment and feature a long-reach positive shutoff spout with an adjustable blowoff element to maintain a clean seal zone and accurate fills. Models 2P-64 and 3P-32 are used over horizontal vacuum formers, positive shutoff spouts and difficult applications such as agitated hoppers, diving spouts, traveling spouts and heated or cooled machines. Hinds-Bock Corp. Bothell, Wash. 877-292-5715 www.hinds-bock.com Charles Ross & Son releases its new line of explosion-proof control panels, designed to be mounted close to the mixer in a hazardous area and
SF&WBtv 74
wired to a variable frequency drive that is installed outside the mixing room. The operator station includes a digital readout for speed and cycle time in a new interface and more compact design. Charles Ross & Son Co. Hauppauge, N.Y. 800-243-7677 www.mixers.com The Deltastyle case packer from BluePrint Automation is newly engineered with automatic changeover, using the company’s signature three- and four-axis Delta robot to case pack snack bags and other flexible packages. The new design mechanically simplifies the system, providing a smaller footprint and a virtually hands-free changeover between different product and case sizes. This case packer also eliminates “fine tuning” that typically takes place after a changeover, providing equipment that bounces back to maximum efficiency after the changeover process is complete. It also eliminates costly change parts, maximizes case utilization and packs small bags at more than 130 beats per minute. BluePrint Automation, Inc. Colonial Heights, Va. 804-520-5400 www.blueprintautomation.com Dematic launches the RapidPick system, a new solution for high-performance split-case order fulfillment. The RapidPick system uses the goods-to-person design— delivering split-case items to an operator in a configuration that allows pick rates of up to 1,000 line items per operator, per hour. Only one SKU is presented to the operator at a time, in the desired sequence. This system is compact and typically uses a 30-65% smaller footprint than other
systems. It’s made up of modular mechanized components—replenishment stations, pick stations, racking and the inventory staging buffer module. Dematic Grand Rapids, Mich. 877-725-7500 www.dematic.us/rapidpick Spiroflow Systems expands its line of conveyors to include DYNAflow tubular chain drag conveyors. Material is moved by heavy-duty discs connected by articulated metal links (chains) equipped for heavy-duty applications. The discs can be made from a variety of materials including steel and cast iron, which enables them to operate at temperatures up to 482oF. The chain drag conveyors are also totally enclosed, resulting in dust- and contamination-free handling. They require minimum energy consumption, can handle hot, cold, wet, dry, hygroscopic or temperaturesensitive materials, produce minimal noise and will not separate blends, among other benefits. Spiroflow Systems, Inc. Monroe, N.C. 704-291-9595 www.spiroflowsystems.com
View videos demonstrating the newest bakery & snack food equipment by visiting www.snackandbakery.com
Snack Food & Wholesale Bakery - August 2011
www.snackandbakery.com
ADVERTORIAL
HOT PRODUCTS GUIDE
2011
The stacked deck sifter allows for quick-screen changeouts. Whether a screen needs to be replaced due to a tear in the screen cloth, a change in mesh specifications or a switch from one product to another, the CS-1 Gyratory Sifter saves time and labor, according to its maker. With the use of only standard hand tools, screen inserts can be changed within minutes. No noxious glue, drying time or tensioning machine required to replace the screens. The CS-1 also provides 2-4 separations of dry product from ¼-in. in size down to 400 mesh with a capacity of 50,000 lb. per hour.
The inspection porthole allows easy access to visually inspect 100% of the screen area without the need to disassemble the sifter. The view port is easy to use and requires no tools; simply unscrew two wing nuts and remove the metal cover plate. The optional view port is available on select decks for the CS-1 sifter and includes front and rear side portholes with cover plates, self-adhering gaskets for the cover plates and nylon wing nuts. It also can be retrofitted to existing CS-1 sifter decks during the repair process. The inspection porthole facilitates maintenance and sanitation and helps to extend the life of the gaskets and decks.
Formerly known under the names of Allis Chalmers, Ferrell Ross and Blount, the all-metal stacked-deck Model CS-1 gyratory sifter is a triedand-true sifter capable of providing 2-4 separations of any dry free-flowing product from ¼-in. in size down to 400 mesh. The CS-1 has the ability to screen up to 50,000 lb. per hour, and its passive, gentle gyratory motion keeps the product in constant contact with the screen for maximum capacity. The CS-1 can provide from 5-35 square feet of screening surface simply by adding additional screen decks. This is all done in a 4x4ft. footprint, minimizing the space required to operate the sifter. The CS-1 gyratory sifter is also BISSC-certified.
The use of the FDA-approved polyurethane screen cleaning balls and cubes help prevent sifter screens from clogging with product. Polyurethane balls are more abrasion-resistant than screen cleaners manufactured from other materials, and provide a longer life. Unlike rubber or neoprene, the balls are non-porous and oil-, moisture- and chemical-resistant. The addition of a stainlesssteel core to the ball and cube make them both magnetic and metal detectable. The poly balls range from 5/8-in. to 2-in. diameter.
contact: Sifter Parts & Service, Inc. Wesley Chapel, Fla.
800-367-3591 www.sifterparts.com
ADVERTORIAL
HOT PRODUCTS GUIDE
2011
Packed with plenty of fiber, antioxidants, vitamins and minerals, whole grains provide the natural nutritional power that today’s consumers seek. GrainEssentials white whole wheat extra fine is milled from carefully selected hard white wheat and soft white wheat using advance technologies to produce a lighter color and sweeter flavor profile than traditional whole wheat. It provides superior performance in a variety of applications, including breads, rolls, bagels, pretzels, pizza, flatbreads, tortillas, pancakes, waffles, cookies, muffins and biscuits.
Gluten-free that’s worry-free. Bay State Milling’s dedicated production area ensures exceptional purity levels, earning the recognition from the Celiac Sprue Association, Omaha, Neb. With BakingEssentials gluten-free, all-purpose flour, customers get an exceptional product and peace of mind. And it’s created in an environmentally controlled production area. Bay State Milling is home to advanced equipment, a quality assurance testing laboratory and warehouse storage to address the growing demand for gluten-free products.
BakingEssentials pizza crust mix is made of high-quality ingredients packaged in one bag for consistent performance and taste. The mix eliminates extra steps and storage costs, resulting in convenience, efficiency and ease of preparation. It offers a versatile and easy-to-customize recipe, and incorporates the company’s most popular pizza flour. Simple changes in shop handling result in variations of thin, thick and pan crusts. This pizza crust mix is ideal for breadsticks, calzones and strombolis, as well as a broadline distributor to pizza and restaurant chains.
Today’s consumers embrace a wide variety of international grain-based foods. Bay State Milling is uniquely qualified to help companies capitalize on this growing trend. Its EthnicEssentials tortilla flour is a superior patent flour milled from carefully selected winter wheat. It has excellent absorption and handling characteristics, and is ideal for producing press, die-cut and hand-stretched tortillas with authentic color and texture.
ADVERTORIAL
contact: Bay State Milling Quincy, Mass.
800-55-FLOUR www.baystatemilling.com
ADVERTORIAL
HOT PRODUCTS GUIDE
2011
Gentle dough handling, precision weight accuracy, quality rounding and high hydration capability are just some of the reasons why bakers want a Koenig Rex. For the past 45 years, the Koenig divider/rounder has been a high-quality machine for the small baker to the large industrial bakeries. As your bakery grows, the Koenig divider/rounder is easily connected to the Koenig automatic roll line. To complete Koenig’s goal for complete customer satisfaction, it offers the total service program, which is a service program tailored to each bakery operation.
ADVERTORIAL
Koenig Bakery Systems Richmond, Va.
804-564-3997 www.koenigusa.com
ADVERTORIAL
HOT PRODUCTS GUIDE
2011
Providing a quality product is a problem bakers must solve to be successful in a competitive market. Concerns about taste, texture, appearance and freshness are just a few of the riddles, and at the heart of these is moisture. Too much water in a baker’s product can lead to problems with shaping, a soggy texture and mold and spore formations in packaging. On the other hand, too little water creates stale, brittle and hard goods. Along with the obstacles associated with water content, determining the moisture level also has proved to be complicated. Deciding when to test, what parts of the product to test and where to test are all difficult choices that need to be made, and changes in these decisions will affect the results obtained from testing. The historical methods used for moisture determination are lengthy processes that hinder the flow of information needed to decide if a product is ready for release or if there is a problem in the baking process. Advances in moisture analyses have dramatically reshaped the antiquated methods of the past. Computrac moisture determination provides a method of moisture analysis by utilizing rapid loss on drying (LOD). Arizona Instrument’s instrumentation is designed for lab precision and production durability. The four-place balance, nickel chromium heating element, built-in cool-down fan make its newest LOD instrument, the MAX 4000XL, fast, accurate and repeatable, allowing for improved process efficiencies and increased production. The results provide vital information used to make adjustments in the baking process and optimizing the quality of goods produced.
The Computrac Vapor Pro series of moisture analyzers uses a relative humidity sensor-based technology to heat a sample of test material in a septum bottle. It correlates to Karl Fischer coulometric titration method (with an oven attachment) in precision and accuracy. The analyzers do not use harmful chemicals or reagents, thus minimizing consumables and making it easy to operate. The Computrac Vapor Pro is recommended for samples with less than 30% moisture. Evolved volatiles are passed to an analysis cell where the moisture content of flowing gas is measured. A microprocessor integrates the varying moisture signal and converts the signal to micrograms of water for display. Results are available in parts per million, percent moisture or total micrograms of water. Arizona Instrument’s prediction algorithm automatically terminates the test in just minutes when sufficient information is collected to allow accurate determination of the sample’s moisture content. The heating range of the Vapor Pro series is 25-275°C. Test parameters such as sample size, heating temperature and test ending criteria can be altered to optimize speed and accuracy. Computrac instrumentation is designed for lab precision and production durability.
ADVERTORIAL
contact: Arizona Instrument LLC Chandler, Ariz.
800-528-7411 www.azic.com
ADVERTORIAL
HOT PRODUCTS GUIDE
2011
alit, based in Marsango, Italy, near Venice, specializes in designing and manufacturing food processing equipment, and provides worldwide installations to proof, bake, cool, freeze and convey food products. Its innovative technology allows the best
flexibility, maximum space saving and highest energy efficiency in the market. In addition, its team and expertise, compiled from some of the greatest companies in North America, are at customers’ disposal to find the best solution for any bakery.
ADVERTORIAL
contact:
alit USA Luverne, Minn.
507-449-0270 www.alit.com
Snack Food Today Exclusive
Hormel’s Fun Family Food Marina Mayer, Executive Editor
or many snackers, the traditional snacking occasion centers around items that are easy to pull out of a bag and pop in the mouth, such as pretzels, popcorn and potato chips. But when the folks at Hormel Foods Sales, LLC saw consumers cutting up pieces of pepperoni into bite-size pieces to use as snacks, they began to carve out a niche within the snack sector that doesn’t really exist. To get into the shopping cart, Hormel conducted focus groups and “shop-alongs” to study how consumers are using pepperoni. Results showed that consumers were using pepperoni beyond the traditional uses of toppings to a pizza. “What we found is that [consumers] are actually using it as a snack or as an ingredient in a meal just as much as they’re using it for pizza,” says Holly Drennan, senior product manager. “So this really gave us the opportunity to expand our usage occasions beyond just pizza and into snacking. And that’s really from where all of our new forms have derived.” As a result, Hormel recently launched a slew of pepperoni meat snacks that offer convenience, portability and an abundance of protein. In March 2009, the Austin, Minn.based company introduced Minis, which are bite-sized pepperoni slices designed to be both a snack and an ingredient to a larger meal, such as pasta, salad, lasagna
F
80
Snack Food & Wholesale Bakery - August 2011
and more. In September 2009, the Pepperoni Minis were launched in a snack-pack option, which incorporates six individually wrapped packages of minis. Each 1-oz. pouch delivers 5 g. of protein. Last year, Hormel presented the Stix line, which encompasses Turkey Pepperoni, Italian Dry Salami and Hard Salami varieties, a lower-calorie Turkey Pepperoni option and Pepperoni Stix & Cheese, which are all packaged similarly to string cheese. “The great thing is that all of these products were formed and inspired by consumers, which is something that we can feel really proud of and know that mom is going to enjoy the products,” Drennan says. This new line of Hormel snacks also increased incremental sales and category expansion. “We’ve actually driven 22% category expansion,” Drennan says. “A portion of that 22% is new users to the category; they’ve never even bought pepperoni before. So clearly, this was speaking to a new occasion that fit their lifestyle.” In addition to the at-the-shelf packaging, Hormel created a merchandising unit that displays color-coded packaging and is placed outside of the snacking aisle. “The primary home for pepperoni would typically be in the lunch meat case or at the deli, but what we’re finding that with the introduction of all of these new items, we’re also getting a lot of secondary placements throughout the store, whether it be the Stix in the snacking aisle or the Minis in the pasta salad aisle. Even now, with some of our individually-served items, we’re moving up front into the cash register area to really take advantage of that impulse purchase. It’s kind of like the
evolution of where pepperoni can play in the store,” Drennan says.
Fun for all ages One of the biggest advantages Hormel has over its competitors is that the Hormel brand is seen as fun family food, Drennan adds. “Being positioned as fun family food really allows us the opportunity to more easily transfer into those usage occasions because of our relationships with mom, the primary grocery shopper,” she notes. The line of snacks itself also targets consumers of all ages, while keeping mom in mind. “The smaller cup size is more convenient store-driven; it’s very single-serve, so it doesn’t compete with other single-serve meat and crackers. It’s more nichey, in that it’s more of a snack on-the-go,” Drennan says. “Our snack trays are very much [for] moms with kids, after-school snacks or [as] the video game snack. We also hear a lot of consumers say that this is the snack that they keep in the car, pop it open and hand it back in the van and use it as a meal replacement or a snack.” While this may be a new direction for the snack industry, it’s also one that’s here to stay. “When you start with the consumer, [the snacking occasion] doesn’t go away from the consumer,” says Steve Venenga, director of marketing and consumer products and refrigerated foods. “Life is just busy, and consumers aren’t slowing down. The traditional meals are still important and will still be there, but when life is just busy, that occasion will still be there as well.” SF&WB
www.snackandbakery.com
Supplier Standpoint
Today’s Conveyor Technology: Comparing Horizontal Motion, Vibratory Conveying
C
onveying in the food industry has become more sophisticated than simply moving product from point A to point B. System layouts, accumulation, feed modulation, product diverting methods, sanitation, operator safety, cross-contamination, sustainability, reliability, energy savings and product quality control are just a few considerations to keep in mind when upgrading a conveyor or ordering a new line. Fortunately, many of these issues can be addressed by choosing between two basic methods of moving product—vibratory or horizontal motion conveying. Exploring the pros and cons of each approach will help you determine which is right for your operation today and in the future.
Feel the vibrations Vibratory conveyors move product by “bouncing” it along the pan. Different magnitudes of amplitude (vertical lift) and frequency (number of times product is pitched forward each minute) produce different product travel rates. Vibratory conveyors use two basic drive types—electromagnetic, which typically produce short amplitude (lift) and high-frequency (speed) movements, and mechanical, which are available in direct or indirect designs. Frequencies are infinitely variable, although a range of 20-30 Hz and amplitudes of 3-5 mm are commonly used. Short amplitude/high frequency is best for light, easy-flowing products such as snack foods, particularly when bed depths and product weights are limited. Normal travel rates are 25–30 ft. per minute. Applications include conveying, spreading and fines removal. Mechanical drives use the opposite set of motions. Long amplitudes up to 13 mm and low frequencies of 11–14 Hz are ideal for conveying heavy or sticky products. These drives are useful for high product throughputs spreading laning and sorting. Direct and indirect variations of mechanical drives deliver fixed-speed conveying and are suited for different applications. For example, direct drives are best for sorting, grading and bi-directional conveying, whereas indirect drives excel in product transfer, dewatering, spreading, laning and fines removal. Because they bounce product, vibratory conveyors offer the following advantages: • Vertically segregate product pieces, allowing for better scalping, grading, sizing, etc. and separation of fines from product. • Spread product across pan width.
www.snackandbakery.com
• High travel rates (with high-amplitude conveyors). • Even out product piles and quickly fill gaps via aggressive movement. • Move sticky products, such as raw potato slices. • Convey product uphill, sometimes as much as 7 degrees. While “bouncing” product is useful for spreading and piece separation, it can be rough on fragile products and separates pre-mixed product blends. The constant impact on the pan shakes seasonings and coatings off products, causing breakage and noise and reducing the quality of finished products. Vibration can also create micro-cracks in products, making them susceptible to eventual breakage. High noise levels are caused by product bouncing in the pan. Also, travel rates decrease as the bed depth or product weight increases, although some conveyors can partially overcome this.
Horizontal motion slides home Instead of bouncing product, horizontal motion conveyors slide it along the pan. This has become the preferred means of transferring and distributing fragile and coated snacks and frozen prepared foods because it provides the following advantages: • Virtually eliminates product breakage and stress fractures. • Does not shake off seasonings and breading. • Eliminates accumulation of seasoning, oil and other coatings in the pan, thus ending unplanned downtime for cleaning. • Offers quiet operation with product. • Maintains product blends and does not segregate product pieces. • Keeps travel rates consistent with bed depths and product weights. • Conveys large quantities of product without
bogging down. • Transmits less vibration, allowing the use of lighter, less expensive support platforms and no ceiling supports. • Accepts different pan lengths and configurations (with certain horizontal motion drives). • While sliding product prevents breakage, coating loss and noise, it also limits the application of horizontal motion conveyors, such as: • Product spreading can only be achieved with specially shaped pans. • Product travel rates are slower than those of aggressive vibratory conveyors but may be faster than high-frequency designs. • Uphill conveying is limited to about 1.5 degrees, although certain products and conveyor combinations can exceed that. • Does not level piles of product without pan modifications. • Difficulty conveying limp or sticky products. Horizontal motion conveyors are available with direct and inertia drives. Direct drives use long strokes producing travel rates up to 40 ft. per minute. In addition to greater throughput/pan size, direct drives’ instant stop and start, modular capability and fast travel rates reduce stale product complaints and improve the efficiency of seasoning applicators, weighers, bagmakers and overall packaging room performance. Meanwhile, inertia drives generally deliver slower product travel rates, have delayed stop and start operation and do not work well in modular and packaging feed applications. All direct drives use mechanisms that change the speed and reverse the motion of the pan. Some drives utilize servo-gearbox, linear motors or rack-and-pinion devices, which are prone to rapid wear. One patented design uses an elliptical pulley and Kevlar-reinforced belt drive that has proven extremely reliable, the lowest energy usage requires no preventative maintenance, and is warranted for five years. That’s why selecting the proper type of direct drive will greatly reduce maintenance and energy usage and improve safety and packaging feed efficiency. Thanks to some fine-tuned conveyor technology though, bakers and snack producers will be able to compare and contrast what works best in their facility. Editor’s Note: This article was written by Blake Svejkovsky, manager of product handling systems for Heat and Control, Inc., Dallas. For more information, go to www.heatandcontrol.com.
August 2011 - Snack Food & Wholesale Bakery
81
Snackandbakery.com
State of the Industry Reports Are Online his year’s State of the Industry reports are now online in digital format. Unlike previous years where we combined both market reports into one issue, this year, we separated them to better bring our readers content, information, statistics and interviews specifically pertaining to their market segment. The State of the Bakery Industry report in June 2011, breaks down trends, new products, packaging innovations, challenges and opportunities and other hot topics pertaining to bread, bars, cookies, tortillas, sweet goods, frozen pizza and frozen baked goods markets. For the July 2011 State of the Snack Industry issue, we uncovered the ins and outs of all things snack, from potato and
T
tortilla chips, to jerky/meat snacks, nuts and trail mix, crackers, popcorn, pork rinds and pretzels. To view both reports in digital format, go to www.snackandbakery. com or contact Ann Kalb at kalba@ bnpmedia.com to obtain a hard copy version. Also, keep an eye out for our September 2011 issue, featuring our Wholesale Baker of the Year. To advertise in Snack Food & Wholesale Bakery, on its website or in Operations Weekly, our free weekly e-newsletter, contact Jeff Heath at
[email protected] or Barb Szatko at
[email protected].
N O V E M B E R 7-9, 2011 INTERCONTINENTAL BUCKHEAD • ATLANTA, GA
PREDICTIONS FOR PACKAGING Packaging Strategies’ NEW Packaging Outlook Summit will offer a window on innovation and showcase trends and predictions in containers and materials. • Discover emerging trends in containers and materials and how they will influence packaging • Hear bold forecasts and predictions from expert sources on the future direction of packaging
Produced By:
• Learn more about the innovation process and how it can support expansion opportunities • Network with top CPG producers/brand owners in a relaxed environment
www.PackagingOutlook.com Media Partner:
82
Snack Food & Wholesale Bakery - August 2011
• Find the latest packaging materials, solutions and services at the Tuesday evening exhibition reception Complete program will be available in July 2011
Supported By:
www.snackandbakery.com
To advertise, contact Suzanne Sarkesian 248-786-1692 •
[email protected] EQUIPMENT FOR SALE
USED WALK-IN-COOLER-FREEZERS REFRIGERATION SYSTEMS – EQUIPMENT HUGE INVENTORY, ALL SIZES Buy Sell - Nationwide - Wholesale Prices
Tel. 216-426-8882 www.awrco.com
[email protected]
TUMBLE BLENDERS IN STOCK “V”AND DOUBLE CONE DESIGNS • Sanitary construction • Many sizes available
LOWEST PRICES!
1-800-243-ROSS www.tumbleblenders.com www.snackandbakery.com
August 2011 - Snack Food & Wholesale Bakery
83
EQUIPMENT FOR SALE
S L L A C E R T C U D O R P T N E PREV 3 P PRODUCTS, R O D U CTS, 1 SOLUTION Switching to Plastic Pallets ·
Improved hygiene, cleaning and sanitizing for WIP areas
·
Chemical & blood resistant
·
Non-porous
·
Substantially longer life compared to wood pallets
·
Improves efficiency in handling
·
Transfer raw ingredients and packaging materials to a hygienic pallet for in house use.
·
Simple 180 degree inversion to recover damaged bags for Good Housekeeping and GNP.
·
Straighten poorly stacked or tilted loads which can become a safety hazard.
·
Exchange finished product from in-house pallets to rental pallets or slip sheets.
·
Cleans wood, plastic & aluminum pallets, totes, containers and freezer spacers
·
Minimizes the risk of introducing Salmonella, E-coli, Listeria, Allergens, dust, dirt and other contaminants
PlasticPallet.com
Pallet Inverter
PalletInverter.com
Pallet Washing System
#HERRYgS )NDUSTRIAL %QUIPMENT #ORP s 600 Morse Ave., Elk Grove Village, IL 60007
800.350.0011 s www.Material-Handling.com
PalletWasher.com
CONSULTING
completely remanufactured tunnel ovens
after photos
Experienced in Rebuilding, Upgrading, Relocation the following Brand Name Equipment: "!+).' /6%.3 s !06 "AKING 2EADCO s 4, 'REEN !-& 7ENER 0LEIDERER 3POONER 6ICAR s 7ERNER ,EHARA s -IDLE "Y -ARSHALL &-%7ELBUILT s &ISH s 4HERMOTRON 5NIVERSAL7ILCO s 7INKLER#HUBCO 4URN +EY !UTOMATION s )NCLUDING #OMPLETE !IR 0OLLUTION #ONTROL s %QUIPMENT 3ALES AND )NSTALLATIONS s !54/-!4%$ 02//&%23 #/.6%9/2 3934%-3 s 3ASIB s "AKE 4ECH 3TUART )* 7HITE s ,ANHAM s 0FENING .ORTHlELD s &(3 #APWAY s 0ULVER 3YSTEMS
We rebuild baking ovens from the ground up. Direct and indirect fired from the small revolving type to 100ft. or longer. For all types of baking performance problems let T&T provide the solutions. If you need to upgrade capacity of an existing tunnel oven, T&T can build and install extensions which might be less expensive than to purchase a new or replacement oven. An older oven, upgraded by T&T with today’s technology can deliver highly competitive baking performance against a new one for less than 50% of cost. We have a current list of ovens on inventory. Contact us for more information, company brochures and photos by phone or the web site.
T&T also offers Factory Mutual and OSHA compliance upgrade work on older baking ovens.
84
Snack Food & Wholesale Bakery - August 2011
Phone: Fax: 847-288-9709 Website: WWW4AND4#%COM E-mail: CONTACT 4AND4#%COM www.snackandbakery.com
EQUIPMENT SERVICES
EQUIPMENT FOR SALE
$"--'3"*/-"45 'SBJOIBTNPSF1SF0XOFE 1BDLBHJOH1SPDFTTJOH NBDIJOFSZUIBOBOZ DPNQFUJUPSBUUIF
-08&45 13*$& (6"3"/5&&% $"--'3"*/(3061
XXXVTFEQBDLBHJOHDPN INGREDIENTS
EQUIPMENT FOR SALE
Southern Perfection Fabrication Quality Bakery Racks, Dollies, Baskets & Trays Advantages: s Competitively Priced s Quality Guaranteed s Small Quantity Orders No Problem
l
*Specia
ie with Free Doll skets 0 ba every 20 t. bough
1-800-237- 4726
www.southernperfection.com
snackandbakery.com www.snackandbakery.com
August 2011 - Snack Food & Wholesale Bakery
85
OVEN RACKS
Your One Stop Shop For... RACKS R RA A
PANS
RACK & PAN WASHERS
Oven Racks Racks, Tray Racks, Pan Racks ANY RACK YOU SLIDE PANS ONTO
SHEET PANS, STAY FLAT PANS, BREAD PAN SETS, BAGUETTE SCREENS
THE RIGHT SIZE WASHER FOR YOUR WASHING NEEDS
9230 Chestnut Ave | Franklin Park IL 60131 | www.ShopCraftRacks.com | (800) 834-8125
Superior Commitment to Excellence Save up to 60% of your valuable work space with Magna Nesting Rack Designs! Magna Industries is a US manufacturer specializing in stainless steel and aluminum equipment solutions for storage, proofing, baking, freezing and transporting products.
Contact the rack company that saves you money and space.
Call 732.905.0957 or visit online at www.magnaindustries.com
86
Snack Food & Wholesale Bakery - August 2011
www.snackandbakery.com
Ad Index Company Website
Company Website
Page
Page
Company Website
Page
A.C. Horn & Co. . . . . . . . . . . . . . . . . . . . . . 26 www.achornco.com
FPSA/Process Expo . . . . . . . . . . . . . . . . . . . 9 www.myprocessexpo.com
Puratos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ADM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OBC www.adm.com
Heat and Control . . . . . . . . . . . . . . . . . . . TT9 www.heatandcontrol.com
QualiTech . . . . . . . . . . . . . . . . . . . . . . . . . TT3
ALIT SRL . . . . . . . . . . . . . . . . . . . . . . . . 22, 79 www.alit.com
Hinds-Bock Corporation . . . . . . . . . . . . . . . 3 www.hinds-bock.com
Rademaker USA, Inc.. . . . . . . . . . . . . . . . . 27
Allied Blending & Ingredients, Inc.. . . . TT24 www.alliedblending.com
Hixson Free Webinar . . . . . . . . . . . . . . . . . 10 http://webinars.snackandbakery.com
AM Manufacturing Company . . . . . . . . TT23 www.ammfg.com
J.C. Ford Company . . . . . . . . . . . . . . . . TT14 www.jcford.com
Arizona Instrument LLC. . . . . . . . . . . . . . . 75 www.azic.com
Key Technology . . . . . . . . . . . . . . . . . . . . . .11 www.key.net
Arr-Tech, Inc. . . . . . . . . . . . . . . . . . . . . . . TT13 www.arr-tech.com
Koenig Bakery Systems www.koenigusa.com
Bay State Milling . . . . . . . . . . . . . . . . .76, IBC www.baystatemilling.com
Kwik Lok . . . . . . . . . . . . . . . . . . . . . . . IFC-1 www.kwiklok.com
BluePrint Automation . . . . . . . . . . . . . . . . 18 www.bpa-flexolutions.com
Lawrence Equipment. . . . . . . . . . . . . . . TT11 www.lawrenceequipment.com
Taconic . . . . . . . . . . . . . . . . . . . . . . . . . . TT10
Brolite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 www.bakewithbrolite.com
Loders Croklaan . . . . . . . . . . . . . . . . . . . . . 59 www.croklaan.com
tna north america . . . . . . . . . . . . . . . . . . . 16
California Raisin Marketing Board . . . . . . . 5 www.LoveYourRaisins.com
MINSA . . . . . . . . . . . . . . . . . . . . . . . . . . TT21 www.minsa.com
Caravan Ingredients . . . . . . . . . . . . . . . TT15 www.caravaningredients.com
Moen Industries . . . . . . . . . . . . . . . . . . . . . 65 www.moenindustries.com
Commercial Creamery . . . . . . . . . . . . . . . 25 www.cheesepowder.com
North Dakota Mill . . . . . . . . . . . . . . . . . . . . 24 www.ndmill.com
Danisco USA Inc. . . . . . . . . . . . . . . . . . . . TT7 www.danisco.com
NuTEC Manufacturing . . . . . . . . . . . . . . TT12 www.nutecmfg.com
FooDesign . . . . . . . . . . . . . . . . . . . . . . . . . 17 www.foodesign.com
Packaging Outlook Summit . . . . . . . . . . . 82 www.PackagingOutlook.com
www.puratos.us
www.qualitechco.com
www.rademaker.com Reiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 www.reiser.com Roplast Industries Inc. . . . . . . . . . . . . . . TT16 www.roplast.com Sifter Parts & Service, Inc. . . . . . . . . . . 30, 78 . . . . . . . . . 19, 77
www.sifterparts.com SnackandBakery.com . . . . . . . . . . . . . . . . 67 www.snackandbakery.com
www.4taconic.com
www.tnasolutions.com Tortilla Industry Association/ TIA Convention . . . . . . . . . . . . . . . . . . . TT18 www.tortilla-info.com Viterra . . . . . . . . . . . . . . . . . . . . . . . . . . . . TT5 www.viterra.com/foodingredients Wire Belt Company . . . . . . . . . . . . . . . . TT17 www.wirebelt.com WP Kemper Bakery Systems, Ltd. . . . . . . 23 www.wpbakerygroupusa.com
Reader & Marketing Services LETTERS Lauren R. Hartman Snack Food & Wholesale Bakery 155 Pfingsten Road, Suite 205 Deerfield, IL 60015 E-mail: hartmanl@ bnpmedia.com SINGLE COPY SALES/BACK ISSUES Ann Kalb T: (248) 244-6499 E-mail:
[email protected] CUSTOM MEDIA Chris Wilson E-mail:
[email protected] T: (248) 244-8264
www.snackandbakery.com
REPRINTS Jill DeVries E-mail: devriesj@ bnpmedia.com T: (248) 244-1726
PRINT & INTERNET ADVERTISING Jeff Heath E-mail: heathj@ bnpmedia.com T: (224) 554-9154
LIST RENTAL Postal contact: Kevin Collopy 800-223-2194 x684;
[email protected]
Barbara Szatko E-mail:
[email protected] T: (630) 527-9927
Email contact: Michael Costantino at 800-223-2194 x748;
[email protected]
CLASSIFIED ADVERTISING Suzanne Sarkesian E-mail: sarkesians@ bnpmedia.com T: (248) 786-1692
BNP Media 155 Pfingsten Road, Suite 205, Deerfield, IL 60015 Phone: (847) 405-4000 Fax: (847) 405-4100
Also publishers of: Beverage Industry, BrandPackaging, Candy Industry, Dairy Foods, Flexible Packaging, Food & Beverage Packaging, Food Engineering, Food Master, Industria Alimenticia, Prepared Foods, Private Label Buyer, Refrigerated & Frozen Foods, Refrigerated & Frozen Foods Retailer, The Deli Advisor, The National Provisioner
August 2011 - Snack Food & Wholesale Bakery
87
The Final Word
When Clipping Coupons Becomes Extreme t used to be that clipping coupons wasn’t cool. Consumers flocked to name-brand items because it’s what they trusted and liked. Shoppers wanted the real deal—no coupons necessary—regardless of the price tag. That was before the economy took a nosedive, forcing Americans to tighten up their spending. Now, the uplift in economical pressures has allowed consumers to again open up their purse strings a bit. But at what cost does all of this take place? For some shoppers, the thought of spending money is still like treading on ice—you never know when the ground is going to crack below you. That’s why many of today’s consumers are turning the once-not-so-cool function of collecting coupons into a trend. Whether it’s aiming to get $10 off a tire rotation, 25% off a restaurant bill or saving $2 on a bag of chips at the grocery store, more and more Americans are able to spend more money because they’re clipping and saving at the register. According to a report by New Yorkbased Nielsen Co., the percentage of consumers who are heavy coupon users is on the rise, reaching 13% of all households in 2010, up 11% from 2009. Of all the coupons used in 2010, 70% were redeemed by enthusiasts, which is defined as those who bought at least 188 items using coupons per year. The coupon craze became even larger of a concept when TLC’s Extreme Couponing debuted, where real-life bargain shoppers save hundreds of dollars in a single trip
I
88
Snack Food & Wholesale Bakery - August 2011
to the grocery store just by submitting an abundance of coupons. Imagine doling out six dozen coupons per shopping trip? I have a hard enough time just keeping my Target Visa in check. After watching several episodes (mainly because this whole concept is intriguing, not because I’m addicted to reality TV, ha ha), I saw how these coupon collectors “stored” their massive amounts of bulk items—underneath the bed, in their children’s closets, in the basement, even in added-on shelving in the garage, similar to the nuclear fallout shelter in Blast from the Past. These coupon collectors have taken the trend of saving money to a whole new level. They’ve become coupon hoarders. But, when is enough enough? Unfortunately, these bundles of redeemed coupons are forcing retailers to experience the bulge left behind after extreme couponers wipe their shelves clean of product and only pay $3 at the register.
Marina Mayer, executive editor
[email protected]
As a result, supermarket chains such as Target and Walgreen’s, to name a few, are updating their coupon policies to stave off those extreme couponers and gain back control of their profits. For example, last year, Walgreen’s Co., Deerfield, Ill., posted rules at the cash registers stating that “management reserves the right to limit quantity of items purchased,” to help prevent customers from wiping them out of product. On June 13, Target Corp. made some enhancements to its coupon policy. “We didn’t so much as change our policy as we added more language to better showcase what we accept when customers submit their coupons,” says Erika Winkels, spokesperson for the Minneapolis-based big box retailer. One of the enhancements was to the buy-one/get-one-free section, indicating that such coupons cannot be combined to make both items free—a strategy that most coupon enthusiasts used to their advantage. “Our policy change wasn’t necessarily tied to the couponing trend. We continuously monitor our policies and want to provide a great experience for our customers,” Winkels says. While coupons have become the cool thing to use at the cash register, these socalled enthusiasts are beginning to ruin the fun for the rest of us who redeem coupons to save a few bucks, but don’t want to hoard home three shopping carts full of items. Thankfully, retailers are making it so us coupon users (not collectors) can still clip and save. SF&WB
www.snackandbakery.com
GrainEssentials®
Performs the way you want. Tastes the way they want. When it comes to whole grains, why settle for less than the whole package? Here, we help you satisfy the trend toward health and wellness deliciously, GrainEssentials® FLOURS: t 8IJUF8IPMF8IFBU9' t 'MPVS#MFOE t 4UPOF(SPVOE8IPMF8IFBU t $SBDLFE8IPMF8IFBU t "OENPSFy #-&/%4 t (SBJO#MFOET t $PNQMFUF1J[[B.JY t .VMUJHSBJO5PSUJMMB$PODFOUSBUF t 8IPMF(SBJO#SFBEFST#BUUFST t "OENPSFy
with quality flours and mixes, and the ability to provide custom solutions. Add in extensive resources and R&D capabilities, and you’ve got a powerful partner. Even so, it’s the performance of our products that makes us the easy choice. Take our White Whole Wheat XF Flour. A terrific substitute for refined white flour, it offers similar texture, consistency, color and flavor. For more information on all of our products, visit baystatemilling.com.
GrainEssentials®
© Copyright 2011
OrganicEssentials®
800-55-FLOUR www.baystatemilling.com
BakingEssentials®
EthnicEssentials™
F
CUST M RMULATIONS Bakers have come to rely on ADM Cocoa for consistency and quality. But what really sets us apart are the added extras you can’t get anywhere else. Like custom formulations. Our technical experts can help you create a one-of-a-kind, categoryleading product your customers will crave. To find out more about how ADM’s technical expertise can give you an advantage, visit us at adm.com/ambrosia.
ADM. Chocolate…and so much more.
For customers around the world, ADM draws on its resources—its people, products, and market perspective—to help them meet today’s consumer demands and envision tomorrow’s needs. © 2011 Archer Daniels Midland Company
800-558-9958 |
[email protected] | www.adm.com
